Composite Brake Disc Collar Structure for Thermal Load and Torque Transfer
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Solution Overview
Problem
Composite brake discs face challenges in thermal deformation and reduced flexural strength due to differing material properties of the friction ring and brake disc hub, leading to asymmetrical stress and reduced torsional rigidity, which affects braking performance and durability.
Innovation Solution
A circular-cylindrical collar on the friction ring provides a firm, torsion-resistant connection to the brake disc hub, with a massive circumferential shoulder in the transition area to enhance thermal and mechanical distribution, and a loose fit connection to simplify production and reduce stress risks, using semi-tubular rivets or screw elements for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If the friction ring extension is arranged radially inside the jacket of the brake disc chamber and the jacket is made thin with openings, then thermal expansion stress is reduced, but torsional rigidity is significantly reduced and force peaks build up
Solution Approach 1:
Instead of placing the friction ring extension inside the jacket as in prior art, the collar is inverted to surround the jacket radially on the outside. This reverses the spatial relationship and allows the collar to act as an external reinforcing element that prevents torsional deformation while still accommodating thermal expansion.
Solution Approach 2:
The solution combines the friction ring (cast iron) with the collar (steel) in a composite structure. The steel collar provides the necessary torsional rigidity and strength, while the cast iron friction ring maintains its friction properties. This composite approach allows each material to perform its optimal function.
2Stability of the object's composition
If the jacket is made thin with openings to increase elasticity, then radial elasticity is improved, but the bottom of the pot must be made relatively thick to withstand torsional stresses
Solution Approach 1:
The brake disc hub is segmented into functionally distinct parts: the thin-walled jacket for radial elasticity and the massive collar for torsional strength. This segmentation allows each part to be optimized for its specific function without compromise.
Solution Approach 2:
Different parts of the brake disc hub have different thicknesses and properties tailored to local requirements: the jacket is thin for elasticity, the collar is thick for torsional resistance, and the pot base thickness is optimized based on local stress conditions rather than being uniformly thick.
3Strength
If a firm connection between friction ring and brake disc hub is provided, then torque transmission is improved, but thermal deformation and shielding effects are amplified
Solution Approach 1:
The connection parameters are optimized to provide firm torque transmission while accommodating thermal changes. The collar's loose fit with radial clearance and use of elastic elements allow the connection to maintain strength during braking while absorbing thermal expansion and contraction without amplifying stress.
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 effectively controls thermal deformation, increases adhesion and torque transmission, improves cooling, and enhances the structural integrity of the brake disc, allowing for a thinner pot base while maintaining mechanical and thermal stability under high loads.
Implementation Method 1
the cooling of the friction ring is improved by the surface of the collar exposed to the wind
Implementation Method 2
Adhesion and torque transmission are even increased in a heated state due to greater thermal expansion of the brake disc hub
Data Source
AI summary
The invention relates to a composite brake disc (1) for a vehicle disc brake, said composite brake disc comprising a brake disc chamber (2) which is made of a first material and is connected to a friction ring (3) made of a different material, wherein the chamber casing (5) and a circular cylindrical collar (7) designed on the friction ring (3) overlap in areas in the radial direction in a connecting region (8) and are penetrated by a number of connecting elements (9, 9, 9'', ...) which are aligned substantially orthogonally to the axis of rotation (A), wherein the composite brake disc (1) is suitable for the transmission of high mechanical and thermal loads in all operating states, whilst being simpler to manufacture, and can also be designed with a particularly thin chamber base and, for this purpose, is designed such that the collar (7) engages around the outer radial portion of the chamber casing (5) in the connecting region (8).