High Thermal Conductivity Disk Brakes for Heat Dissipation
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Solution Overview
Problem
Current disk brake systems face challenges in heat dissipation, leading to reduced brake pad life and friction coefficient due to high surface temperatures, and incomplete disengagement of outer brake pads, which affects fuel efficiency and weight reduction.
Innovation Solution
A disk brake assembly with a floating caliper and a rotor made of materials with high thermal conductivity and expansion, where the rotor expands during braking and quickly cools upon cessation, ensuring complete disengagement of the outer brake pad, and a solid disc design with metal claddings and a thermal conductive hat for efficient heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the disk uses traditional materials with low thermal conductivity, then the brake pad life and friction coefficient are maintained, but the heat dissipation is insufficient leading to high surface temperatures
Solution Approach 1:
The patent changes the thermal conductivity parameter of the disk material from traditional low-conductivity materials to high-conductivity materials, fundamentally altering the heat transfer characteristics to achieve effective heat dissipation while maintaining brake pad performance
Solution Approach 2:
The patent employs composite material structures including the high thermal conductivity disk material combined with specific brake pad compositions, creating a material system that optimizes both heat dissipation and friction characteristics
2Power
If the outer brake pad is designed to engage firmly during braking, then braking efficiency is improved, but incomplete disengagement occurs after braking reducing fuel efficiency
Solution Approach 1:
The patent utilizes thermal expansion of the high-conductivity disk material during braking to ensure firm pad engagement, and subsequent thermal contraction after braking to achieve complete pad disengagement, eliminating drag and improving fuel efficiency
Solution Approach 2:
The patent creates a dynamic engagement-disengagement system where the brake pad contact state changes automatically with temperature variations, transitioning from firm engagement during braking to complete disengagement after braking
3Temperature
If the disk is designed with ventilation passageways for heat dissipation, then heat dissipation is improved, but the device complexity and potential rust issues increase
Solution Approach 1:
The patent removes the ventilation passageway feature from the disk design, extracting the potential problems of complexity and rust susceptibility while relying on the high thermal conductivity material property to achieve heat dissipation through a simpler solid disk 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 solution effectively reduces brake pad wear, maintains fuel efficiency, and lowers working temperatures, making the brake system suitable for front and rear applications without relying on vents, which reduces rust and maintains consistent heat dissipation.
Implementation Method 1
the rotor is made at least in part of a material having a thickness and a coefficient of thermal expansion and a thermal conductivity, such that a complete 100 kilometer per hour, 0.9 gross vehicle weight braking causes the disk to expand in thickness by at least 0.15 mm
Implementation Method 2
a complete 100 kilometer per hour, 0.9 gross vehicle weight braking causes the disk to expand in thickness by at least 0.15 mm and to cool to shrink in thickness, relative to its expanded thickness, by at least 0.1 mm within 60 seconds of the cessation of braking
Data Source
AI summary
An automotive disk brake assembly installed in an automobile having a wheel. The assembly includes a floating caliper supporting an inner and outer brake pad and a brake rotor having a disk, and a hat, and wherein the hat is bolted to the wheel. A hydraulic cylinder is adapted to push the inner brake pads into the disk surface, causing the floating caliper to move bringing the outer brake pad into contact with the disk. Finally, the rotor is made such that a complete 100 kilometer per hour, 0.9 gross vehicle weight braking causes the disk to expand in thickness by at least 0.15 mm and to cool to shrink in thickness, relative to its expanded thickness, by at least 0.1 mm within 60 seconds of the cessation of braking, in an ambient temperature of less than 30° C.