Ventilated Brake Disc Assembly With Spot-Welded Cooling Spacer
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Solution Overview
Problem
Existing ventilated disc brake systems face issues with heat dispersion and mechanical resistance, leading to deformation, corrosion, and uneven wear, particularly in high-performance applications, and are costly and labor-intensive to produce.
Innovation Solution
A braking band and disc design featuring plates welded to a ventilation spacer using capacitive spot welding at discreet points, minimizing structural discontinuities and maintaining a high cooling efficiency while using a cost-effective industrial process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If ventilated discs are designed with multiple ventilation channels to improve heat dissipation, then cooling efficiency is improved, but the mechanical resistance and structural integrity of the braking band deteriorate
Solution Approach 1:
The braking band is segmented into multiple discrete ventilation channels rather than a continuous open structure. This segmentation allows heat to be dissipated through multiple separate pathways while the material between channels maintains structural integrity and mechanical strength.
Solution Approach 2:
The ventilation channels are strategically positioned and sized to provide adequate cooling in critical areas while maintaining sufficient material density in load-bearing regions. The channel geometry is optimized to balance thermal management requirements with mechanical strength requirements locally.
2Temperature
If the braking band structure is optimized for heat dissipation, then cooling efficiency is improved, but the mechanical resistance deteriorates
Solution Approach 1:
The disc utilizes composite construction with a braking band made from materials optimized for both thermal dissipation and mechanical strength. The combination of material properties allows simultaneous achievement of high cooling efficiency and high mechanical resistance that cannot be obtained with single materials.
3Productivity
If brazing is used to join plates to improve production efficiency, then productivity is improved, but the braking surfaces are deteriorated due to preloading effects and corrosion
Solution Approach 1:
The brazing process is completely removed from the manufacturing method. Instead of joining plates through brazing, the invention uses a monolithic braking band structure or alternative joining methods that do not involve brazing, thereby eliminating all associated problems of preloading, surface deterioration, and corrosion.
Solution Approach 2:
The invention replaces expensive and problematic brazing processes with simpler, more reliable manufacturing methods that may involve less expensive materials or processes, achieving both cost reduction and improved reliability.
4Strength
If welding is used to join plates with fins, then mechanical resistance is improved, but structural discontinuities cause uneven wear and noise
Solution Approach 1:
The welding process is removed from the manufacturing method. The invention eliminates welding-related structural discontinuities by using alternative construction approaches that do not require joining separate plates through welding, thereby preventing the source of uneven wear and noise generation.
Solution Approach 2:
Instead of joining multiple plates together (which creates discontinuities), the invention inverts the approach by using a continuous, monolithic braking band structure where possible, or alternative joining methods that create more uniform stress distribution and fewer structural discontinuities.
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 provides enhanced braking comfort, improved cooling efficiency, and extended disc life with uniform wear, while being lightweight and corrosion-resistant, suitable for heavy applications.
Implementation Method 1
plates welded to a ventilation spacer using capacitive spot welding at discreet points
Data Source
AI summary
A method for manufacturing a brake disc includes providing at least one sheet of predefined thickness, blanking a first disc-shaped portion in the at least one sheet adapted to make a first plate of a ventilated braking band, blanking a second disc-shaped portion in the at least one sheet adapted to make a second plate of the ventilated braking band, blanking a third portion in the at least one sheet adapted to make at least one ventilation spacer for the ventilated braking band, drawing the third portion by shaping first and second protrusions, forming opposite first and second recesses adapted to make ventilation channels, connecting the first disc-shaped portion to the first protrusion by discontinuous weld spots, and connecting the second disc-shaped portion to the second protrusion by discontinuous weld spots.