Water Cooled Brake Disc With Segmented Inlet Ports
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Solution Overview
Problem
Existing liquid-cooled disc brakes face inefficiencies in heat transfer and coolant flow, leading to reduced performance and reliability in braking applications due to inadequate cooling of the wear plate.
Innovation Solution
The design incorporates a coolant flow cavity with two inlet ports 180° apart and two outlet ports 90° from the inlets, along with radially aligned coolant entry channels and staggered rows of pin projections to create turbulent flow and enhance heat transfer, ensuring effective cooling of the wear plate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single coolant inlet and outlet configuration is used, then the device complexity is low, but the coolant flow rate and cooling efficiency are insufficient
Solution Approach 1:
The single coolant inlet is segmented into multiple inlet ports (first and second coolant inlets) positioned at different locations, and the single outlet is segmented into multiple outlet ports (first and second coolant outlets). This segmentation allows coolant to enter and exit at multiple points, increasing flow distribution and cooling efficiency without requiring a completely new system architecture.
Solution Approach 2:
The patent combines multiple coolant flow paths into a unified cooling system where coolant from multiple inlets merges and flows through the cooling cavity to multiple outlets. This merging approach maintains system simplicity while achieving enhanced cooling through increased flow rate and better heat distribution.
2Reliability
If coolant flows directly through the cavity without turbulence promotion, then the device complexity is low, but the heat transfer from the wear plate to coolant is insufficient
Solution Approach 1:
The patent introduces turbulence promotion elements that create chaotic, turbulent flow patterns in the coolant as it moves through the cooling cavity. This turbulence enhances heat transfer between the wear plate and coolant by disrupting boundary layers and increasing fluid mixing, effectively acting as a mechanical means to improve thermal exchange without complex active control systems.
Solution Approach 2:
The patent utilizes hydraulic principles by designing the cooling cavity and flow paths to naturally promote turbulent flow through geometric features and flow direction changes. The system leverages the hydraulic properties of the coolant itself, using flow velocity and path design to generate turbulence that enhances heat transfer without requiring external mechanical actuators.
3Quantity of substance
If coolant inlets are positioned close together, then the device complexity is low, but the pressure drop and flow resistance are high
Solution Approach 1:
The patent positions the coolant inlets asymmetrically within the cooling cavity rather than symmetrically close together. The first and second coolant inlets are located at different positions and orientations, creating asymmetric flow paths that reduce interference between incoming coolant streams and minimize pressure drop, thereby enabling higher overall flow rates.
Solution Approach 2:
The patent distributes coolant inlets and outlets across different spatial dimensions within the cooling cavity. Rather than positioning all ports in a single plane or location, the design utilizes three-dimensional spacing and angular distribution (e.g., ports at different radial positions and angles), which reduces flow resistance by creating more efficient, less congested flow paths.
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 increases coolant flow rate and improves cooling efficiency, allowing the brake to operate longer and more reliably by maintaining lower temperatures at the contact surface, thus enhancing braking performance.
Implementation Method 1
improved heat transfer from the components to the coolant is promoted by creating a turbulent flow of the coolant in the coolant flow cavity
Implementation Method 2
Heat can be transferred from the brake plate to the pin projections and the coolant
Implementation Method 3
Heat can be transferred from the brake plate to the pin projections and the coolant
Implementation Method 4
Heat can be transferred from the brake plate to the pin projections and the coolant
Data Source
AI summary
A braking system includes at least one rotating disc and at least one brake disc. A brake disc wear plate is configured for retarding engagement with a rotating disc brake pad. Each brake disc has an annular coolant cavity associated with two inlet ports spaced apart 180° and two outlet ports spaced apart 180°. Each outlet port is spaced 90° from an adjacent inlet port. Each port leads to a respective radial channel. The channels are in open flow communication with each other. Inlet port coolant received into an inlet channel flows in both angular directions toward the outlet ports. Heated coolant gathered at an outlet channel is a mixture of coolant received from both inlet channels. Each inlet channel includes a stepped configuration to divert additional coolant to the outermost portion of the coolant cavity, which portion underlies the outermost (and hottest) portion of the wear plate.