Brake Disc Flat-Flange Joint for Thin Lightweight Rotor Hats
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Solution Overview
Problem
Existing brake discs face challenges in achieving a stable mechanical connection between lightweight brake pots and friction rings without compromising material thickness, as recesses for connecting elements would further reduce the already thin material.
Innovation Solution
Designing the edge and/or collar of the brake pot to be flat in the area of the connecting element, maintaining material thickness while ensuring a stable mechanical connection through a planar design, which can be achieved via pressing or deep-drawing processes, and using connecting elements like rivets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If recesses are created in the brake pot for connecting elements, then a mechanical connection between the friction ring and brake pot is achieved, but the material thickness is further reduced compromising structural integrity
Solution Approach 1:
The brake pot is pre-formed with a flat edge region before the connecting elements are installed. This preliminary shaping of the edge to be flat in the connection area allows subsequent riveting or welding without requiring material removal, thus maintaining material thickness while ensuring proper connection geometry
Solution Approach 2:
The geometric parameter of the brake pot edge is changed from curved to flat specifically in the connection area. This parameter change is achieved through forming processes that create a flat edge region, enabling stable mechanical connection with connecting elements while preserving the overall material thickness and structural integrity
2Weight of moving object
If the brake pot is made from lightweight material with thin gauge, then the overall weight of the brake disc is reduced, but the ability to provide stable mechanical connection is compromised
Solution Approach 1:
The brake pot exhibits different geometric qualities in different areas: the majority of the brake pot maintains thin gauge lightweight construction, while the edge region in the connection area is formed to be flat and provides enhanced local structural support. This local quality differentiation enables stable mechanical connections while preserving overall lightweight characteristics
Solution Approach 2:
The flat edge region is pre-formed in the lightweight brake pot material before assembly. This preliminary action creates an optimized connection surface that provides adequate mechanical support for connecting elements without requiring thicker material throughout the entire brake pot, thus maintaining lightweight design while ensuring connection reliability
Data Source
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AI summary
The invention relates to a brake disc comprising a friction ring consisting at least partially of a first material (101a/b) and a brake rotor hat (103) consisting at least partially of a second material that is different from the first material. In addition, the friction ring comprises a flange (203) formed in the axial direction and the flange is connected to the brake rotor hat by means of at least one connection element (102). The brake rotor hat and/or the flange is formed flat at least in the region of the at least one connection element (102). In this way, a stable mechanical connection is created between the flange (203) of the friction ring and the brake rotor hat (103).