Vented Brake Disc Channels for Balanced Cooling and Low Coning
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Solution Overview
Problem
Conventional vented brake discs with cooling duct inlets on only one side suffer from poor cooling performance and stress concentration due to narrow inlets, leading to heavy designs and disc coning issues at high temperatures.
Innovation Solution
A vented brake disc design featuring cooling channels on both the inboard and outboard sides with alternating blocking parts to prevent communication between channels, ensuring equal air flow and reducing stress concentration, while maintaining a balanced design to prevent airflow constriction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If inlets of cooling ducts are provided in only one side (inboard or outboard), then the structure is simpler, but cooling performance is poor
Solution Approach 1:
The brake disc is divided into three separate braking plates (first inboard braking plate, intermediate braking plate, and outboard braking plate) with cooling ducts provided in each. This segmentation allows cooling air to be introduced from both the inboard side and outboard side through distributed inlets, significantly improving cooling performance while maintaining reasonable structural complexity through modular construction
Solution Approach 2:
The patent transitions from providing cooling ducts in only one dimension (single-sided inlets) to providing cooling ducts in multiple dimensions (both inboard and outboard sides). By extending the cooling duct configuration to utilize both faces of the brake disc, the patent achieves superior cooling performance through multi-directional airflow
2Temperature
If inlets of cooling ducts are provided on both inboard and outboard sides, then cooling performance is enhanced, but the brake disc becomes heavy
Solution Approach 1:
By segmenting the brake disc into three separate braking plates with cooling ducts distributed throughout, the patent achieves effective cooling from both sides without requiring excessive material. The segmented structure allows for optimized material distribution that reduces overall weight compared to a solid design, while still providing dual-sided cooling capability
Solution Approach 2:
The patent employs a vented structure with multiple cooling ducts and channels that create a porous-like configuration within the solid brake disc material. This allows airflow penetration through the disc thickness, achieving effective cooling without requiring a solid heavy construction, thus reducing weight while maintaining cooling performance
3Length of stationary object
If inlets of cooling ducts are narrowed to meet thickness specifications, then the brake disc thickness is controlled, but stress is concentrated on support arms
Solution Approach 1:
The patent divides the braking function across three separate braking plates connected by multiple support arms, distributing the mechanical loads and stresses throughout the structure. This segmentation prevents stress concentration on single support arms by creating multiple load paths, allowing the use of narrower cooling duct inlets while maintaining structural integrity and meeting thickness specifications
Solution Approach 2:
The patent applies different structural characteristics to different regions: the support arms are designed with specific geometry to handle bending stresses, while the braking plates contain the cooling ducts with appropriate wall thicknesses. This localized optimization allows narrow cooling duct inlets without compromising overall structural strength, as each region is designed for its specific function
4Stability of the object's composition
If cooling ducts are provided to prevent disc coning, then thermal deformation is reduced, but the structure becomes more complex
Solution Approach 1:
The brake disc is segmented into three braking plates with cooling ducts distributed in each plate, allowing uniform heat dissipation across the entire disc structure. This segmentation prevents localized thermal gradients that cause coning, while the modular nature of the segmented design keeps structural complexity manageable through repeated standard components
Solution Approach 2:
The patent addresses disc coning by extending the cooling duct configuration from a single-plane arrangement to a multi-dimensional arrangement spanning both inboard and outboard sides. This three-dimensional cooling duct network ensures uniform thermal distribution throughout the disc thickness and radius, preventing thermal deformation while utilizing efficient space utilization
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
Enhances cooling performance by providing balanced airflow through both sides, reducing disc coning at high temperatures and preventing stress concentration, thus offering improved thermal management and structural integrity.
Implementation Method 1
a first air flow through the first cooling channel from the inboard side to the outboard side
Implementation Method 2
effectively discharge thermal energy generated by the frictional force
Data Source
AI summary
A vented brake disc according to the present disclosure comprises a first braking plate having a first inner surface and a first outer surface; a second braking plate parallel with and spaced apart from the first braking plate, the second braking plate having a second outer surface, and a second inner surface facing the first inner surface; a plurality of channels defined by two walls adjacent to each other, the channels communicating with the inner peripheral space of the first braking plate and with the inner peripheral space of the second braking plate; a hat portion having a mounting surface and a peripheral portion extended axially from the mounting surface; a first blocking part preventing outboard communication of any one of the channels, the first blocking part connecting the peripheral portion to the first braking plate; and a second blocking part preventing inboard communication of the channel adjacent to the channel where the outboard communication is prevented by the first blocking part, the second blocking part connecting the peripheral portion to the second braking plate. The channels are provided between the first inner surface of the first braking plate and the second inner surface of the second braking plate. The first blocking part and the second blocking part are provided along the peripheral portion.