Ventilated Disc Brake Band Modules for Cooling and Noise Reduction
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Solution Overview
Problem
Existing ventilated disc brake systems face challenges in efficiently dissipating heat generated during braking, leading to deformation, material cracking, and increased noise due to vibrations, which existing solutions fail to adequately address while maintaining mechanical resistance and airflow efficiency.
Innovation Solution
A braking band with a unique configuration of connecting elements, including ridges and fins, that enhance airflow turbulence and modify natural vibration modes to reduce noise and vibrations, while maintaining high cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the number and shape of ventilation channels are increased to improve heat dissipation, then cooling efficiency is improved, but the mechanical strength and structural integrity of the braking band deteriorate
Solution Approach 1:
The braking band is segmented into multiple discrete connecting elements (pillars, fins, ribs) distributed throughout the structure. This segmentation allows ventilation channels to be created between these elements without compromising overall structural integrity, as each element independently contributes to mechanical strength while collectively providing adequate cooling
Solution Approach 2:
Different regions of the braking band are given different local qualities: connecting elements are concentrated in regions requiring higher structural strength, while larger ventilation channels are permitted in regions where cooling is prioritized. This spatial variation in structural density optimizes both mechanical strength and heat dissipation efficiency
2Power
If friction material is applied to increase braking efficiency, then braking performance is improved, but heat generation increases causing deformation and material cracking
Solution Approach 1:
The heat generated by friction during braking, which is normally a harmful effect causing deformation and cracking, is converted into a beneficial cooling opportunity. The ventilation channels are specifically designed to capture and channel this heat away through forced convection, transforming the harmful thermal energy into useful cooling airflow that prevents overheating and structural damage
3Strength
If connecting elements are added to improve structural integrity, then mechanical resistance is improved, but airflow turbulence and cooling efficiency may be reduced
Solution Approach 1:
Connecting elements are designed with curved surfaces and aerodynamic profiles rather than sharp edges. This curvature reduces flow separation and turbulence losses in the ventilation channels, allowing air to flow more smoothly around and through the connecting elements. The result is maintained structural integrity with minimized energy loss to turbulence
Solution Approach 2:
The connecting elements are specifically shaped to function as aerodynamic flow guides, using principles of pneumatic design to direct airflow efficiently through the ventilation channels. The elements act as both structural support and flow management components, optimizing the balance between mechanical strength and cooling performance
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 solution effectively reduces vibrations and noise, ensuring improved braking comfort by separating tangential vibration modes and maintaining high disc cooling efficiency through increased airflow turbulence.
Implementation Method 1
crossed by airflows according to a centrifugal direction during the rotary motion of the disc itself
Implementation Method 2
the friction between the pads of the brake calipers and the braking surfaces of the braking band generates a high amount of heat
Implementation Method 3
enhance airflow turbulence and modify natural vibration modes
Data Source
AI summary
A braking band has a first plate and an opposite second plate having inner surfaces delimiting a gap, outer surfaces forming braking surfaces, and a plate body. The plates are joined by connecting elements. At least one plate has at least one ridge projecting into the gap without reaching the opposite plate. The ridge extends from a first connecting element to an adjacent connecting element, and along a circumferential direction, the connecting elements and the ridge being groupable in modules circumferentially distributed along the gap. A first module has three adjacent connecting elements connected by two ridges projecting from the first plate into the gap without reaching the second plate. A second module has three adjacent connecting elements connected by two ridges projecting from the second plate into the gap without reaching the first plate. A third module has at least one connecting element free of ridge connection.