Floating Disk Brake Hub Thermal Management
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Solution Overview
Problem
Current disk brake hub assemblies face thermal distortion issues due to the high heat conductivity of materials like aluminum, leading to brake failure and increased wear, and existing designs exacerbate these problems by constraining rotor expansion, causing coning and fatigue.
Innovation Solution
The disk brake hub assembly incorporates a brake hub with torque members and axial preload springs that allow the brake disk to 'float' relative to the hub, minimizing heat transfer and accommodating thermal expansion, while maintaining torque transfer and proper orientation through axial qualifying surfaces and cooling channels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If aluminum material is used for brake hub to reduce weight, then weight is reduced, but heat conductivity increases causing thermal distortion
Solution Approach 1:
The brake hub is segmented into multiple components: an aluminum hub body for weight reduction, a separate brake disk for heat dissipation, and thermal barrier elements (spacers, torque members with gaps) that divide the thermal path. This segmentation allows the lightweight aluminum hub to avoid direct thermal contact with the brake disk, preventing thermal distortion while maintaining weight benefits.
Solution Approach 2:
Thermal barrier spacers and torque members act as intermediary elements between the aluminum hub and the brake disk. These intermediaries provide mechanical connection for torque transfer while blocking direct heat conduction paths, allowing the system to achieve both lightweight construction and thermal management.
2Force
If brake disk is rigidly bolted to hub, then torque transfer is improved, but thermal distortion and coning increase
Solution Approach 1:
The mounting system transitions from a rigid fixed connection to a dynamic floating connection. The brake disk is allowed to move axially and radially within defined limits, accommodating thermal expansion and contraction. Torque members with gaps and spring elements provide flexible torque transfer while permitting the brake disk to maintain its circular shape during thermal cycles.
Solution Approach 2:
The mechanical connection parameters are changed from rigid fixed positioning to flexible floating positioning. The torque members incorporate gaps and spring elements that allow the brake disk to change position dynamically in response to thermal conditions, preventing constraint-induced distortion while maintaining adequate torque transfer.
3Force
If torque member extends deeply into brake disk, then torque transfer is improved, but heat transfer to hub increases
Solution Approach 1:
The torque member design extracts the torque transfer function from a deep embedded connection and separates it from the thermal conduction path. Torque members engage the brake disk at the outer diameter where less heat is present, and transfer torque through gap-filled connections rather than continuous material paths, reducing heat transfer to the hub while maintaining torque transfer efficiency.
4Temperature
If cooling channels are added to brake disk, then heat dissipation is improved, but manufacturing complexity increases
Solution Approach 1:
The brake disk incorporates cooling channels that create a porous or semi-porous internal structure. This allows coolant flow through the disk for enhanced heat dissipation. The channels are integrated into the disk manufacturing process using techniques such as precision casting or additive manufacturing, which can create complex internal geometries without significantly increasing manufacturing complexity.
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 reduces thermal stress on the hub and brake disk, preventing brake failure and wear by allowing the disk to expand and contract freely, while ensuring consistent braking performance and extended component lifespan.
Implementation Method 1
a plurality of ribs extending between the first and second plates to define a plurality of cooling channels therebetween
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
a torque member extending between the hub and disk, the torque member extending axially inboard from the braking surface a distance not more than the thickness of the second plate plus about 50% of the spacing between the first and second plates
Implementation Method 4
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 5
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
AI summary
A brake hub assembly for coupling to a wheel rim includes a hub body and a brake disk coupled to the hub body. The hub body and brake disk are shaped to allow maximum airflow through the brake disk during operation of the vehicle.