Integral Thermal Fuse Brake Disk for Overheat Torque Release
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Solution Overview
Problem
Conventional aircraft brakes can overheat and potentially cause fires or thermal damage due to accidental application while the engine or propeller is still running, leading to excessive energy generation and heating.
Innovation Solution
A brake disk with a fusible material section that disconnects from the shaft when its temperature exceeds a predetermined maximum operating temperature, acting as a 'thermal fuse' to prevent further torque transmission and reduce heat buildup.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the brake is applied while the engine or propeller is still running, then the braking function is activated, but excessive heat is generated leading to potential fires or thermal damage
Solution Approach 1:
The patent changes the physical state of the fusible material section from solid to liquid/melted when the temperature reaches its melting point, causing the brake disk to disconnect from the shaft. This parameter change (phase transition) automatically limits the temperature rise by stopping torque transmission, thereby preventing excessive heat generation and potential fires while maintaining reliable braking operation under normal conditions.
Solution Approach 2:
The fusible material section acts as an intermediary element between the shaft and the braking surface. It transmits torque during normal operation but melts and disconnects the braking surface from the shaft when excessive temperature is reached, thereby mediating the protection against thermal damage without requiring external control systems.
2Reliability
If a fusible material section is added to the brake disk, then thermal protection is provided, but the device complexity increases
Solution Approach 1:
The patent merges the thermal protection function directly into the brake disk structure by integrating the fusible material section as an inherent part of the brake disk. This combining of the protective function with the existing structure avoids adding separate complex safety systems, thereby providing thermal protection with minimal increase in device complexity.
Solution Approach 2:
The fusible material section provides self-service thermal protection by automatically melting and disconnecting the braking surface from the shaft when the temperature reaches its melting point. This self-activating mechanism eliminates the need for external sensors, control systems, or manual intervention, thereby providing reliable thermal protection without significant complexity.
3Reliability
If the fusible material section is made from material with lower melting point than the braking surface, then thermal fuse function is achieved, but the material selection constraints increase
Solution Approach 1:
The patent applies local quality by using different materials with different melting points for different sections of the brake disk. The fusible material section uses a material with lower melting point specifically for thermal protection, while the braking surface uses materials with higher melting points for withstanding braking temperatures. This localized material differentiation enables thermal fuse functionality while maintaining the necessary performance of each specific section.
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 fusible material section effectively limits temperature rise during braking operations, mitigating the risk of overheating and preventing thermal damage or fires by disconnecting the braking surface from the shaft when excessive heat is generated.
Implementation Method 1
the fusible material section for transmitting torque between the braking surface and a shaft while a temperature of the fusible material section is below the maximum operating temperature of the fusible material section
Implementation Method 2
when the temperature of the fusible material section raises above the maximum operating temperature of the fusible material section, the fusible material section is configured to no longer transmit torque between the braking surface and the shaft
Implementation Method 3
the fusible material section is configured to no longer transmit torque between the braking surface and the shaft
Data Source
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AI summary
A brake disk and method of making a brake disk are disclosed. The brake disk (52,52a) defines an annular shape having a radially inner side and a radially outer side. The brake disk (52) further comprises: a radially outer braking surface (56), the braking surface having a maximum operating temperature; a fusible material section (58) radially inward from and connected to the braking surface. The fusible material has a maximum operating temperature, the fusible material section suitable for transmitting torque between the braking surface and a shaft (12). The maximum operating temperature of the braking surface is higher than the maximum operating temperature of the fusible material section. When the temperature of the fusible material section raises above the maximum operating temperature of the fusible material section, the fusible material section is configured to no longer transmit torque between the braking surface and the shaft.