Brake Disc Chamber Recesses for Compact Friction Ring Mounting

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Solution Overview

Problem

Existing brake disc designs for smaller motor vehicles require significant radial space for connection elements, limiting their applicability due to the need for larger brake disc dimensions.

Innovation Solution

The brake disc design incorporates axially oriented material recesses at the outer circumference of the brake disc chamber jacket to accommodate connection devices such as rivets, allowing for a minimized connection area in the axial direction, enabling a smaller brake disc diameter by using light metal materials and specific connection methods like riveting and centering shoulders.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If connection devices are used to connect the friction ring to the brake disc chamber, then the brake disc can be assembled with separate components allowing material optimization, but the radial space requirement increases

Engineering Contradiction:

Improvematerial optimizationVSAvoidradial space

Core Design Contradiction:

Ease of manufactureVSLength of stationary object

Solution Approach 1:

The connection devices are reoriented from radial extension to axial extension. The recesses in the brake disc chamber jacket guide the connection devices to extend primarily in the axial direction rather than radially, thereby reducing the radial space requirement while maintaining the separate component assembly advantage for material optimization

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The connection devices are nested within axially oriented recesses in the brake disc chamber jacket. These recesses accommodate the connection devices, allowing them to be housed within the structural envelope of the brake disc chamber rather than extending outward radially, thus minimizing radial space occupation

Inventive Principle:

Principle #7Nested doll (Nesting)

2Length of stationary object

If the brake disc diameter is reduced for smaller vehicles, then the space requirement is minimized, but the connection area between friction ring and brake disc chamber becomes insufficient

Engineering Contradiction:

Improvebrake disc diameterVSAvoidconnection area

Core Design Contradiction:

Length of stationary objectVSArea of stationary object

Solution Approach 1:

The connection area is extended in the axial dimension rather than requiring increased radial dimension. By orienting connection devices axially and providing axially oriented recesses, the brake disc chamber achieves sufficient connection area for smaller diameters by utilizing the axial direction for connection functionality

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS11346415B2Brake disc for a vehicle

Publication Date: 2022.05.31 BAYERISCHE MOTOREN WERKE AG

AI summary

A brake disc is provided for a disc brake, which consists of a brake disc chamber and at least one friction ring connected to the latter via connecting devices. A jacket of the brake disc chamber is provided with sections of reduced wall thickness and/or apertures. These sections and/or apertures are axially directed material recesses which are located on the outer circumference of the brake disc chamber jacket and serve for placing the connecting devices as close as possible to the brake disc chamber jacket.