Angled Brake Rotor Mounting Slots for Thermal Expansion
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Solution Overview
Problem
Rigidly secured brake rotors in disk brake systems can warp due to thermal expansion, necessitating a design that allows movement between the rotor and wheel to mitigate this issue.
Innovation Solution
A disk brake system with a rotor mounting slot that is angled relative to the wheel's radial axis, featuring a mounting post and spring washers for secure attachment and vibration damping, allowing for controlled movement and thermal expansion compensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the rotor is rigidly secured to the wheel, then the attachment strength is improved, but the rotor warps due to thermal expansion
Solution Approach 1:
The mounting slot is designed at an angle (1-5 degrees) relative to the radial axis, transforming the rigid connection into a dynamic floating mount that allows the rotor to move radially with thermal expansion while maintaining secure attachment. This dynamic adjustment prevents warping by accommodating expansion forces.
Solution Approach 2:
The angled mounting slot changes the geometric parameter of the mounting configuration, allowing controlled radial movement of the rotor relative to the wheel. This parameter change enables the rotor to expand thermally without constraint while maintaining secure attachment through the angled slot geometry.
2Adaptability or versatility
If the mounting slot is angled relative to the radial axis, then thermal expansion compensation is improved, but the mounting complexity increases
Solution Approach 1:
The angled mounting slot introduces a localized geometric feature (1-5 degree angle) specifically at the mounting interface, while the rest of the rotor and wheel maintain their standard simple circular geometries. This localized quality change provides thermal compensation without requiring complex modifications throughout the entire brake system.
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 angled mounting slot design effectively manages thermal expansion of the rotor, preventing warping while maintaining secure attachment and providing vibration damping, thus enhancing brake system reliability and performance.
Implementation Method 1
As the caliper applies braking forces to the rotor, the rotor heats up and expands. If the rotor is rigidly secured to the wheel, such thermal expansion can cause the rotor to warp.
Implementation Method 2
mounting post positioned in the mounting slot to secure the rotor to the wheel. The mounting post preferably includes a substantially cylindrical portion positioned in the mounting slot and an exterior surface positioned to engage the first sidewall.
Data Source
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Figure 2
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AI summary
The present invention provides a disk brake system comprising a wheel defining a rotational axis, a caliper mounted adjacent the wheel, and a rotor mounted for rotation with the wheel and engageable by the caliper. The rotor includes a mounting slot defined by first and second sidewalls, the first sidewall defining a first axis that substantially intersects the rotational axis, and the second sidewall defining a second axis that is substantially parallel to the first axis. Preferably, the mounting slot defines a center axis that intersects a radial axis of the wheel at an angle of at least 1.5 degrees, preferably at least 2.0 degrees and more preferably about 2.5 to 3.9 degrees. Preferably, the mounting slot has a width and a length that is at least 10% larger, preferably at least 15% larger, and more preferably about 20 % larger than the width.