Ventilated Disc Brake Band Pin Geometry for Cooling and Crack Resistance
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Solution Overview
Problem
Disc brakes with ventilated discs face issues of heat buildup leading to deformation and increased risk of cracks due to inadequate cooling and structural weakening, existing solutions failing to effectively balance cooling efficiency and crack resistance.
Innovation Solution
A braking band design with modified pin elements and ventilation channel geometry that increases the heat exchange surface and heat transfer coefficient, enhancing air flow turbulence and heat dissipation without increasing the braking band's weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the ventilation channel geometry is modified to increase cooling efficiency, then heat dissipation is improved, but the structural strength may be weakened leading to crack formation
Solution Approach 1:
The patent applies local quality by creating pin elements with non-uniform cross-sections along their length. The pin elements have different geometric characteristics at different positions, allowing the root portions to maintain structural strength while the distal portions optimize fluid dynamics and heat transfer. This localized differentiation resolves the contradiction by strengthening critical areas without compromising overall cooling efficiency.
Solution Approach 2:
The patent employs curved and rounded geometric features in the pin element design, including rounded edges and non-linear cross-sectional transitions. These curved geometries reduce stress concentration points that would otherwise lead to crack initiation, while maintaining the enhanced fluid flow paths needed for effective cooling. The curvature principle simultaneously addresses both strength and thermal management requirements.
2Temperature
If the heat exchange surface is increased to improve cooling, then temperature control is enhanced, but the device complexity increases
Solution Approach 1:
The pin elements serve multiple functions simultaneously: they provide structural support connecting the braking band plates, act as ventilation channel walls defining fluid flow paths, and function as heat transfer surfaces. This multi-functionality increases the heat exchange surface area without adding separate cooling components, thereby improving temperature control while avoiding increased device complexity.
Solution Approach 2:
The braking band is segmented into multiple pin elements distributed across the ventilation channel, creating distributed heat exchange surfaces. This segmentation approach increases total heat transfer area compared to a single large cooling structure, while the modular nature of multiple smaller pin elements keeps manufacturing and assembly complexity manageable.
3Temperature
If the pin elements have complex cross-sections to enhance heat transfer, then heat transfer coefficient is increased, but manufacturing difficulty increases
Solution Approach 1:
The patent utilizes parameter changes by varying the cross-sectional dimensions and geometric parameters of the pin elements along their length. The cross-section transitions from one geometry at the root to a different geometry at the distal end, optimizing heat transfer and fluid flow characteristics. These gradual parameter changes can be achieved through standard manufacturing techniques like progressive machining or forging, balancing enhanced heat transfer with manufacturing feasibility.
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 design reduces maximum working temperatures by 22.7% and delays crack formation, maintaining structural integrity while improving thermal stress resistance and cooling efficiency.
Implementation Method 1
the inner surfaces delimit, together with the pins or the fins, a ventilation channel for cooling the disc, being crossed by the air according to a centrifugal direction during the rotation motion of the disc itself
Implementation Method 2
the braking action provided by the pads against the braking surfaces of the disc generate heat, therefore an increase of temperature to the extent of making the disc itself incandescent
Data Source
AI summary
Some pin elements may have a substantially circular cross section, forming a circumference-shaped edge. Other pin elements may have a substantially rhomboidal cross section, forming a symmetric rhombus-shaped edge with respect to a radial direction and a circumferential direction orthogonal to this radial direction. Yet other pin elements may have a substantially circular cross section, forming a circumference-shaped edge.