Brake Disc Connecting Means for NVH Reduction
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Solution Overview
Problem
Existing brake disc assemblies with tight connecting means suffer from asymmetric force distribution, high NVH levels, and risk of bushing loss, particularly when using materials like carbon/ceramic brake discs with metal bells, leading to reduced stability and lifetime.
Innovation Solution
A connecting means featuring a form-locked and/or force-locked element with a bushing having a shoulder and loss prevention, along with a distance element providing homogeneous area force and temperature isolation, ensuring the bushing is not bent during tightening and preventing loss, with a design that allows for a lower NVH level and stable force transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a bushing with two plane sections and a cut is used (DE 19940570 A1), then loss prevention of the bushing is achieved, but asymmetric force distribution and high NVH levels occur
Solution Approach 1:
The bushing is divided into two separate functional components: a distance element that provides thermal isolation and a bushing body with loss prevention features. This segmentation allows the distance element to distribute forces symmetrically while the bushing retains the brake disc ring, resolving the contradiction between retention and force distribution.
Solution Approach 2:
A distance element is introduced as an intermediary component between the bell and the brake disc ring. This mediator provides thermal isolation and ensures homogeneous area force distribution, eliminating the asymmetric force transmission that caused high NVH levels in the prior art.
2Object-generated harmful factors
If a bushing with one plane section and distance element is used, then homogeneous force distribution is achieved, but loss prevention of the bushing is lost
Solution Approach 1:
The functions of force distribution and loss prevention are merged into a single integrated bushing design. The bushing has a loss prevention feature (protrusion or thread) that engages with the brake disc ring, while the overall structure maintains homogeneous force distribution, combining the advantages of both prior art solutions.
3Ease of manufacture
If the bushing is bent during tightening, then connection is achieved, but stability and lifetime are reduced
Solution Approach 1:
The bushing is pre-formed with a loss prevention feature (such as a protrusion or thread) that engages with the brake disc ring before tightening. This preliminary design ensures that the bushing cannot be lost during assembly or operation, eliminating the need for bending during tightening and preserving both ease of manufacture and component lifetime.
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 achieves a homogeneous area force distribution, prevents bushing loss, and significantly reduces NVH levels, enhancing the stability and lifetime of the brake disc assembly while allowing for the use of various materials, outperforming multi-part systems with springs.
Implementation Method 1
a distance element (130) arranged between the brake disk ring (300) and the bell (200)... having the function of thermal isolation
Data Source
AI summary
A brake disc assembly including a brake disk ring, a bell and a connecting mechanism between the brake disk ring and the bell, wherein the connecting mechanism includes a form-locked and/or force-locked connecting element in an axial direction DO of the brake disc ring, the connecting mechanism comprises a bushing for the connecting element and a distance element arranged between the brake disk ring and the bell, wherein the bushing includes a shoulder and a loss prevention, wherein the bushing further includes a region A1 provided for the brake disk ring and a region A2 provided for the bell, wherein the region A1 has an average expansion E4 in an direction perpendicular to DO and the region A2 has an average expansion E2 in an direction perpendicular to DO.