Modular Brake Disc Assembly for Heat Transfer and Friction
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Solution Overview
Problem
Aircraft brake disc assemblies face challenges in balancing mechanical strength, corrosion resistance, and thermal properties, as materials with high thermal stability often lack efficient heat transfer and strength, while strong materials may not provide adequate friction or thermal dissipation.
Innovation Solution
The brake disc assembly comprises a structural core with pockets and removable friction pads featuring bosses that engage with the core, allowing for efficient torque transfer and heat dissipation, with materials tailored for mechanical, thermal, and friction properties, ensuring improved strength and frictional performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If materials with high thermal stability are used for the brake disc, then thermal resistance is improved, but heat transfer efficiency deteriorates
Solution Approach 1:
The brake disc is divided into two distinct parts: a structural core made of thermally stable material (e.g., carbon-carbon composite) and friction pads made of materials with high heat transfer efficiency (e.g., metal or ceramic composites). This segmentation allows each component to be optimized for its specific function - the core provides thermal stability while the friction pads provide efficient heat transfer away from the friction interface.
2Strength
If strong materials are used for the brake disc, then mechanical strength is improved, but frictional performance deteriorates
Solution Approach 1:
The brake disc is segmented into a structural core and friction pads. The structural core is made of strong materials (e.g., carbon-carbon composite or metal matrix composite) to provide mechanical strength and structural integrity, while the friction pads are made of materials with superior frictional properties (e.g., sintered metal or ceramic composites) to provide effective braking force.
Solution Approach 2:
Different regions of the brake disc have different material properties optimized for their specific functions. The structural core has high strength and thermal stability, while the friction pads have high friction coefficient and heat transfer efficiency. This local quality differentiation resolves the contradiction between overall strength and local frictional performance.
3Device complexity
If a monolithic brake disc structure is used, then device complexity is reduced, but thermal management capability deteriorates
Solution Approach 1:
The brake disc is segmented into a structural core and removable friction pads. This segmentation enables superior thermal management because the friction pads can be made of materials with high thermal conductivity to rapidly conduct heat away from the friction interface, while the core provides structural support. The modular design also allows for optimized thermal pathways.
Solution Approach 2:
The friction pads are designed as consumable components that can be replaced when worn or degraded. This allows the system to maintain optimal friction and heat transfer properties throughout its service life, while the durable structural core is retained and reused, separating the lifecycle of friction materials from the structural component.
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 configuration enhances the brake disc's strength, frictional properties, and heat dissipation capabilities, allowing for effective braking and thermal management, reducing stress and temperature extremes on the friction pads.
Implementation Method 1
the structural core may be configured to provide strength to the brake disc assembly and remove heat from the friction pads
Implementation Method 2
The friction pads may be configured to provide a friction surface for the brake disc assembly
Data Source
AI summary
An article includes a structural core, one or more friction pads, and a plurality of elongated fasteners. The structural core includes two core surfaces and a plurality of pockets extending between the core surfaces. Each friction pad includes a pad surface and a friction surface opposite the pad surface. Each pad surface includes a planar pad surface configured to contact the core surface and a plurality of bosses extending from the first planar pad surface and including a bore. Each planar pad surface is at least about 50% of a surface area of the respective first and second pad surfaces. The plurality of bosses engages with the plurality of pockets to position the respective first and second friction pads relative to the structural core. The plurality of elongated fasteners passes through bores of corresponding bosses of friction pads to fasten the friction pads to the structural core.