Disk Brake Hub Assembly Thermal Isolation via Floating Torque Members
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current disk brake hub assemblies face thermal distortion issues due to the high thermal conductivity of materials like aluminum, leading to brake failure and increased wear, as well as strength loss at elevated temperatures, which is exacerbated by the constrained mounting of disk rotors.
Innovation Solution
A disk brake hub assembly with improved thermodynamic isolation is achieved through the use of torque members, spacers, and axial preload springs that allow the brake disk to 'float' relative to the hub, minimizing heat transfer and maintaining orientation, while using lightweight materials like aluminum to reduce rotating mass.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If aluminum material is used for the hub to reduce weight, then the weight of the hub is reduced, but heat transfer to the hub increases causing thermal distortion and brake failure
Solution Approach 1:
The hub assembly is segmented into thermally isolated zones: the brake disk is separated from the aluminum hub body by torque members with low thermal conductivity, creating a thermal barrier that allows the hub to remain lightweight while preventing heat transfer to thermally sensitive components
Solution Approach 2:
Torque members serve as intermediary elements between the brake disk and the aluminum hub. These torque members are specifically selected to have low thermal conductivity, acting as thermal mediators that transmit mechanical torque while blocking heat transfer from the hot brake disk to the temperature-sensitive aluminum hub
2Strength
If the rotor is rigidly mounted to the hub, then the rotor is securely attached, but thermal distortion of the rotor is exacerbated causing cone shape deformation
Solution Approach 1:
The mounting system transitions from a rigid fixed connection to a dynamic floating connection. The torque members allow the brake disk to float axially and radially, enabling the rotor to expand and contract freely in response to thermal changes while maintaining secure mechanical attachment for torque transmission
Solution Approach 2:
The thermal parameters of the mounting system are changed by selecting torque members with low thermal conductivity. This parameter change allows the rotor to be securely mounted while minimizing heat transfer, thereby preventing thermal distortion and maintaining rotor shape stability during braking operations
3Strength
If mounting bolts constrain the rotor at one friction face, then the rotor is firmly secured, but thermal induced distortion into cone shape is magnified
Solution Approach 1:
The single-face bolted connection is segmented into a multi-point floating connection using multiple torque members distributed around the rotor perimeter. This segmentation allows the rotor to be firmly secured through distributed attachment points while preventing concentrated thermal stress that causes cone-shaped distortion
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 effectively limits heat transfer to thermally sensitive components, reduces stress from thermal expansion, and maintains braking torque transfer, thereby enhancing the durability and efficiency of the brake system by preventing thermal distortion and strength loss.
Implementation Method 1
an axial preload spring configured to contact the brake disk and the hub and allow the brake disk to float relative to the hub
Implementation Method 2
The disks or rotors are the heat sink for a vehicle's kinetic energy that is converted to thermal energy during the braking process
Implementation Method 3
The mounting bolts constrain the inside diameter of the rotor while the outside diameter is free to grow as the rotor heats up
Data Source
Figure 1
Figure 1a
Figure 2
AI summary
A brake hub assembly including a brake hub and a brake disk having a first brake surface, a second brake surface spaced axially from the first brake surface, and a plurality of ribs extending between the first and second brake surfaces. Where the brake hub is thermally isolated from the brake hub by various combinations of spacers, torque pins, torque lugs, and the like.