Composite Brake Disc Collar Structure for Thermal Load Rigidity
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Solution Overview
Problem
Composite brake disks face challenges in thermal deformation and stress asymmetry due to differing material properties of the friction ring and brake disk pot, leading to reduced flexural strength and torsional rigidity, which can cause the friction ring to tilt and affect tribological quality.
Innovation Solution
A circular-cylindrical collar on the friction ring engages radially around the pot shell, providing a firm, torsionally and flexurally rigid support, and a solid encircling shoulder in the transition region enhances material strength and heat distribution, while a clearance fit simplifies production and reduces stress risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the brake disk pot is made thin-walled to reduce weight, then the weight is reduced and wheel can be attached closer to wheel hub, but the flexural strength is reduced and friction ring can easily tilt
Solution Approach 1:
The brake disk is divided into two separate components: a thin-walled steel brake disk pot and a friction ring. The friction ring is made as a separate component with a collar that engages around the pot shell, allowing each part to be optimized independently for weight and strength requirements.
Solution Approach 2:
The thin-walled brake disk pot and the friction ring are combined through the collar engagement mechanism. The collar of the friction ring engages radially around the pot shell, creating a unified structure that maintains flexural strength while keeping the pot walls thin.
2Adaptability or versatility
If the shell is made thin with apertures or reduced wall thickness to increase elasticity, then radial elasticity is improved, but torsional rigidity is reduced and force/stress peaks build up
Solution Approach 1:
The brake disk pot features local thickness variations: thin walls in most areas for elasticity and weight reduction, but a locally thickened pot base for torsional rigidity and stress resistance. This localized quality differentiation resolves the contradiction between overall elasticity and local strength requirements.
3Adaptability or versatility
If different materials are used for friction ring and brake disk pot to optimize function, then functional optimization is achieved, but joining becomes challenging due to different physical properties
Solution Approach 1:
The brake disk is segmented into two functionally optimized components made from different materials: a steel brake disk pot and a gray cast iron friction ring. This segmentation allows each material to be selected for its optimal functional properties while simplifying the joining approach.
Solution Approach 2:
The collar engagement mechanism acts as an intermediary connection between the steel pot and cast iron friction ring. This mechanical engagement method avoids direct material joining challenges while transmitting torque effectively between the dissimilar materials.
4Stress or pressure
If the friction ring extension is arranged radially inside the shell to reduce thermal expansion stress, then asymmetrical stress is reduced, but the shell must be made thin which reduces torsional rigidity
Solution Approach 1:
Instead of placing the friction ring extension inside the shell, the collar is inverted to engage radially around the outside of the pot shell. This inversion maintains thermal stress reduction benefits while allowing the shell to maintain adequate thickness for torsional rigidity.
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 enhances the brake disk's ability to handle mechanical and thermal loads, improves torque transmission, and reduces the risk of thermal deformation, resulting in increased safety and durability with a thinner pot base and improved cooling.
Implementation Method 1
the cooling of the friction ring is improved by the collar surface that is exposed to the relative wind
Implementation Method 2
different materials sometimes have very different physical properties, such as, for example, coefficients of thermal expansion
Data Source
AI summary
A composite brake disk for a vehicle disk brake, including a brake disk pot which is formed from a first material and is connected to a friction ring made of a different material, wherein the pot shell and a circular-cylindrical collar formed on the friction ring overlap in some regions in the radial direction in a connecting region and are penetrated by a plurality of connecting elements oriented substantially orthogonally with respect to the axis of rotation, wherein the composite brake disk is suitable for transmitting high mechanical and thermal loads in all operating states, while being simple to manufacture, and can also be formed with a particularly thin pot base and, for this purpose, enables the collar to engage radially on the outside around the pot shell in the connecting region.