Brake Disc Coupling Structure for Noise and Cooling Improvement
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Solution Overview
Problem
Existing brake discs experience rumbling noise and poor cooling performance due to structural issues at the connection points between the hat and braking parts, leading to vibration and heat dissipation problems.
Innovation Solution
A brake disc design featuring a hat part with lateral insertion portions and a braking part with corresponding coupling portions, where the hat part is made of a different material and positioned to reduce noise, and a manufacturing method involving casting and anti-rust treatment to ensure proper coupling and heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple connection parts are disposed in the braking part to couple the hat part and braking part, then the coupling strength is improved, but dimensional waveforms are formed causing rumbling noise
Solution Approach 1:
The invention extracts the coupling parts from the braking part and relocates them to the hat part. This separation removes the source of dimensional waveforms from the braking surface, eliminating rumbling noise while maintaining coupling strength through the hat part's structure.
Solution Approach 2:
The coupling function is transitioned from the braking part's radial dimension to the hat part's axial dimension. The coupling parts protrude from the hat part's inner diameter surface along the axial direction, creating a different spatial arrangement that avoids interference with the braking surface.
2Stability of the object's composition
If coupling parts are positioned in braking surfaces, then the structural integrity is improved, but air flow is blocked causing deterioration in cooling performance
Solution Approach 1:
The coupling parts are extracted from the braking surfaces and relocated to the hat part. This removal restores unobstructed air flow paths through the braking part's hollow portion, improving cooling performance while the hat part's coupling parts maintain structural integrity.
Solution Approach 2:
The brake disc is segmented into distinct functional zones: the hat part handles coupling functions with protruding coupling parts, while the braking part maintains open hollow portions for air flow. This segmentation allows each component to optimize its primary function without interference.
3Weight of moving object
If the hat part is made of lightweight material to reduce unsprung mass, then fuel economy is improved, but noise occurs at the coupling position
Solution Approach 1:
The noise-generating coupling parts are extracted from the braking part and relocated to the lightweight hat part. This allows the hat part to maintain its weight reduction benefit while the coupling function is performed in a location that does not generate rumbling noise.
Solution Approach 2:
The hat part serves as an intermediary component that bridges the wheel hub and the braking part. By placing coupling parts on the hat part rather than the braking part, it mediates the connection in a way that prevents direct transmission of dimensional waveforms to the braking surface.
Data Source
AI summary
The present disclosure relates to a brake disc including a braking part having a circular plate shape having a hollow portion and a plurality of coupling portions protruding and extending from an inner diameter surface thereof, and a hat part disposed in the hollow portion and having a plurality of insertion portions protruding laterally, in which the plurality of coupling portions is respectively coupled to the plurality of insertion portions, and the coupling portion of the braking part and the insertion portion of the hat part are joined to only one of an outboard portion or an inboard portion of the braking part. According to the present disclosure, it is possible to reduce noise occurring at a position at which the hat part and the braking part are coupled to each other and improve cooling performance.