Brake Rotor Clip Reinforcement for Perpendicular Rivet Loads
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Solution Overview
Problem
Existing rotor clips for brake assemblies are prone to bending or breakage due to high forces acting perpendicular to the force transmission, and they can be expensive and difficult to manufacture and install, with potential damage to the rotor disk during replacement.
Innovation Solution
A clip design featuring a reinforcement member extending from the inner surface of the end portion between the two sides, with apertures in the sides to secure the clip to the rotor lug using rivets, which reduces bending and enhances stress distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional rotor clips are secured using rivets or pins, then the clip can be attached to the rotor lug, but the fasteners are subject to high perpendicular forces causing bending or breakage
Solution Approach 1:
The reinforcement member is divided into multiple discrete elements (first reinforcement member and second reinforcement member) positioned at different locations within the receptacle, allowing each segment to independently support rivets and distribute loads, preventing any single point from bearing excessive perpendicular forces
Solution Approach 2:
Reinforcement members are strategically positioned at specific locations within the receptacle where rivets will be installed, providing localized structural support exactly where needed to prevent rivet bending or breakage under high perpendicular forces, rather than uniformly strengthening the entire clip
2Strength
If rivets with protruding heads are used to secure the clip, then the clip can be firmly attached, but the rivet heads can be damaged or cause damage to other parts
Solution Approach 1:
The reinforcement members are installed beforehand within the receptacle to provide a cushioning or protective interface between the rivet heads and the clip structure, absorbing or distributing the concentrated forces that would otherwise be transmitted directly to the rivet heads and surrounding areas, preventing damage before it occurs
3Strength
If multiple rivets are used to secure the clip, then the attachment strength is improved, but the assembly process becomes more complex and time-consuming
Solution Approach 1:
The reinforcement members are pre-installed within the receptacle during clip manufacturing, so that during assembly only the rivets need to be installed without any additional preparation steps. This preliminary positioning of reinforcement elements simplifies the overall assembly process while maintaining the strength benefits of multiple rivets
4Reliability
If reinforcement is added to the clip to prevent rivet bending, then the durability is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The reinforcement members are designed as thin, planar elements that can be easily formed and installed within the receptacle, providing substantial structural reinforcement while minimizing material usage and manufacturing complexity. The thin-film approach allows for cost-effective production while achieving the desired durability improvement
Data Source
Figure 1
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Figure 4~7
AI summary
A clip for a rotor disk of a brake assembly, the clip (300) arranged to fit over an end of a lug of the rotor disk, the clip having two opposing sides (311, 312) and an end portion (303) across the two opposing sides, and a top portion (301), the top portion, the sides and the end portion each having an inner surface and an outer surface, and the inner surface of the top portion, the sides and the end portion together defining a receptacle (320) to receive the rotor lug, in use, the clip having at least one aperture (322) in each of the sides; the clip further comprising a reinforcement member (500) extending from the inner surface of the end portion internal of the receptacle, between the two sides.