Laser-Textured Brake Carrier Disc for Stable Pad Bonding
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Solution Overview
Problem
Existing brake pad carriers face challenges in achieving stable adhesive connections at high speeds and reducing noise during braking, while also being cost-effective and environmentally friendly.
Innovation Solution
A carrier disk arrangement featuring laser-processed discs with specific surface depressions for improved adhesive bonding, combined with a damping means and a steel hub with internal teeth, allows for enhanced adhesion and noise reduction. The discs are made of aluminum, and the hub part is designed for axial displacement, with a concentric arrangement for efficient braking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional smooth surfaces are used on brake discs, then manufacturing is simpler, but adhesive bonding stability at high speeds deteriorates
Solution Approach 1:
The brake disc surface is modified locally by creating depressions only in the adhesive bonding areas, while other areas remain smooth. This localized surface modification improves adhesive bonding stability without significantly complicating the overall manufacturing process.
Solution Approach 2:
Traditional mechanical surface roughening methods are replaced with laser processing to create the depressions. This substitution enables precise control of depression geometry and depth, improving adhesive bonding while maintaining manufacturing efficiency through automated laser processes.
2Ease of manufacture
If conventional machining methods are used to create surface depressions, then manufacturing is easier, but environmental emissions increase
Solution Approach 1:
Conventional mechanical machining methods are replaced with laser processing to create surface depressions. This substitution eliminates dust and particulate emissions associated with mechanical cutting and grinding, while maintaining the ability to efficiently create the required surface geometry.
Solution Approach 2:
The laser processing method utilizes controlled oxidation and vaporization of material to create depressions, replacing mechanical removal methods that generate harmful dust emissions. This approach processes material through thermal oxidation rather than mechanical cutting.
3Reliability
If uniform circular depressions are used, then manufacturing is simpler, but adhesion improvement is limited
Solution Approach 1:
Different depression shapes (circular, square, rectangular, kidney-shaped) are used in different locations on the brake disc surface. This local variation optimizes adhesive adhesion in specific areas while maintaining overall manufacturing simplicity through standardized laser processing parameters.
Solution Approach 2:
The depressions are arranged in periodic patterns around the brake disc, with regular spacing in the circumferential and radial directions. This periodic arrangement ensures uniform braking force distribution while allowing varied depression shapes to enhance adhesion.
4Force
If brake pads are firmly bonded to discs, then braking force is improved, but noise during braking increases
Solution Approach 1:
The brake assembly is segmented into distinct components: brake pads, damping means, and carrier disc assembly. The damping means acts as an intermediate element that allows firm bonding of brake pads to discs for improved braking force, while simultaneously reducing noise transmission.
Solution Approach 2:
A damping means is introduced as an intermediary element between the brake pads and the carrier disc assembly. This intermediary component provides vibration damping and noise reduction while maintaining the necessary firm bonding for effective braking force transmission.
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 a stable adhesive connection at high speeds, reduces noise, and ensures cost-effective production with fewer environmental emissions, while maintaining a uniform braking force and low moment of inertia.
Implementation Method 1
The first depressions are produced and/or processed by means of a laser
Implementation Method 2
a first friction lining is glued to the surface area of the first of the two discs and/or is adhesively bonded to the first disc
Implementation Method 3
a part having a braking surface, the brakeable shaft having external teeth or being non-rotatably connected to a component having external teeth
Data Source
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AI summary
The invention relates to a carrier disc assembly for a brake assembly and to an electromagnetically actuatable brake assembly with a carrier disc assembly. The carrier disc assembly has a hub part (1), two friction linings, and two discs (2), wherein the discs are connected to the hub part, in particular by means of axially aligned screws (3), and each of the discs has a respective surface region which has first depressions. A first friction lining is adhered to the surface region of the first of the two discs and/or is adhesively connected to the first disc, and a second friction lining is adhered to the surface region of the second of the two discs and/or is adhesively connected to the second disc.