Sub-Frame Integrated Brake Cooling Duct Assembly
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Solution Overview
Problem
Existing vehicle brake cooling systems face challenges in effectively cooling brake components during high-performance braking, as additional ducts for air supply can increase weight and negatively impact aerodynamics, leading to reduced fuel efficiency and handling.
Innovation Solution
A duct assembly integrated within the vehicle's sub-frame and suspension components to capture air from beneath the vehicle and direct it to the brake assembly, enhancing cooling while minimizing aerodynamic drag.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If additional ducts are provided to channel air to brake components for enhanced cooling, then the cooling effectiveness is improved, but the vehicle weight increases and aerodynamic performance deteriorates
Solution Approach 1:
The duct assembly is integrated with the vehicle sub-frame structure, merging the cooling duct function with the existing structural component. This eliminates the need for separate, additional ducts while still providing effective air channeling to the brake components, thereby avoiding extra weight.
Solution Approach 2:
The sub-frame structure serves multiple functions: it provides structural support for the vehicle and simultaneously acts as a cooling duct system by incorporating hollow sections that channel air to the brakes. This multi-functionality reduces the need for dedicated cooling components that would add weight.
2Temperature
If additional ducts are provided to channel air to brake components for enhanced cooling, then the cooling effectiveness is improved, but the aerodynamic performance and fuel efficiency deteriorate
Solution Approach 1:
By integrating the duct assembly into the sub-frame, the design eliminates separate aerodynamic components that would create drag. The sub-frame's existing aerodynamic profile is preserved while incorporating cooling functionality, thus minimizing energy loss.
3Temperature
If supplemental cooling apparatus such as ducts are added to increase air supply to brakes, then the cooling capacity is improved, but the device complexity increases
Solution Approach 1:
The duct assembly is merged with the sub-frame structure, combining two functions (structural support and air channeling) into a single integrated component. This reduces the total number of separate parts and simplifies the overall cooling system architecture.
Solution Approach 2:
The sub-frame structure is designed to serve dual purposes: providing structural support and acting as an air channeling system. This multi-functionality reduces device complexity by eliminating the need for separate dedicated cooling ducts.
4Temperature
If ducts are provided to direct air to brake assembly, then the cooling effectiveness is improved, but the aerodynamic drag increases impacting handling
Solution Approach 1:
The duct assembly is integrated into the sub-frame, utilizing the existing structural component's aerodynamic profile rather than adding separate drag-inducing ducts. This maintains vehicle handling characteristics while providing effective brake cooling.
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 solution increases air supply to brake components for effective cooling without compromising aerodynamic performance, thus maintaining vehicle efficiency and handling.
Implementation Method 1
capture air from beneath the vehicle and direct it to the brake assembly, enhancing cooling
Implementation Method 2
Friction is created by the contact between the brake disc and brake pad
Implementation Method 3
Some of the heat generated by the frictional contact may be transferred to the air
Data Source
AI summary
Some embodiments are directed to a duct assembly for cooling a brake assembly of a vehicle. The duct assembly can include a hollow inlet section that is disposed at the vehicle sub-frame and configured to capture air from beneath the vehicle sub-frame; and a hollow intermediate section that communicates with the inlet section so as to form a contiguous channel therewith. The intermediate section can be disposed entirely within the vehicle sub-frame. A hollow outlet section can communicate with the intermediate section so as to form a contiguous channel between the inlet, intermediate and outlet sections. The outlet section can be disposed and configured to direct the air captured by the inlet section to the front end of the brake assembly to thereby cool at least a portion of the brake assembly.