Brake Disc Flange Connection Using Deformable Intermediary
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Solution Overview
Problem
Existing brake disks face challenges in achieving a stable mechanical connection between the collar of the friction ring and the brake pot, particularly in lightweight constructions where material thickness is limited, leading to potential gaps and reduced structural integrity.
Innovation Solution
Incorporating a plastically deformable intermediate piece between the brake pot and the connecting element, which deforms under pressure to form a stable mechanical connection, eliminating gaps and enhancing structural stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a connecting element is used to join the collar to the brake pot, then a mechanical connection is achieved, but gaps arise between the connecting element and the brake pot surface due to curved vs flat surface geometry
Solution Approach 1:
A plastically deformable intermediate piece is introduced between the connecting element and the brake pot. This intermediate piece acts as a mediator that can be compressed to close the gap between the flat brake pot surface and the curved collar surface, ensuring stable mechanical connection without requiring recesses in the brake pot.
Solution Approach 2:
The intermediate piece undergoes plastic deformation under compression, changing its physical state from a loose fit to a tightly compressed state. This parameter change allows the intermediate piece to adapt to the gap geometry and maintain continuous contact pressure, eliminating gaps while preserving the thin-walled structure of the brake pot.
2Manufacturing precision
If recesses are made in the brake pot to close gaps, then surface contact is improved, but material thickness is further reduced which compromises structural integrity
Solution Approach 1:
Instead of modifying the brake pot structure by creating recesses, the solution introduces an intermediate piece as a mediator. This piece can be compressed to fill gaps without requiring any material removal from the brake pot, thereby preserving the structural integrity of the thin-walled brake pot while achieving complete surface contact.
3Weight of moving object
If the brake pot is made from lightweight material with thin walls, then weight is reduced, but the ability to form stable connections with connecting elements is compromised
Solution Approach 1:
The intermediate piece undergoes plastic deformation under compression, changing its density and volume to fill gaps and create uniform contact pressure. This parameter change allows the system to maintain reliable connections in thin-walled lightweight brake pots without compromising connection stability.
Solution Approach 2:
The plastically deformable intermediate piece serves as a mediator that compensates for the limitations of thin-walled lightweight brake pots. It ensures stable mechanical connections by adapting to surface geometries and maintaining contact pressure, enabling the use of lightweight materials without sacrificing connection reliability.
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 closes gaps and establishes a stable mechanical connection between the collar and brake pot, enhancing the structural integrity of lightweight brake disks, even with thin materials, by using a plastically deformable intermediate piece that deforms under pressure.
Implementation Method 1
the intermediate piece is not an elastically deformable washer or sleeve but is deformed plastically under the pressure of the connecting element
Data Source
AI summary
A brake disc includes a friction ring consisting at least partially of a first material and a brake rotor hat consisting at least partially of a second material that is different from the first material. The friction ring includes a flange formed in the axial direction, wherein the flange is connected to the brake rotor hat by means of at least one connection element. An intermediate piece is provided between the surface of the brake rotor hat in contact with the connection element and the connection element. In this way, a stable mechanical connection is created between the flange of the friction ring and the brake rotor hat.