Brake Disc Insert with Retainer for Wear Reduction
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Solution Overview
Problem
Existing wheel brake systems face issues with mechanical stresses on brake discs due to rotor drive keys, leading to wear and potential rivet failure, which compromises the attachment and surface integrity of the brake disc.
Innovation Solution
A drive insert assembly comprising a clip and retainer that securely attaches to the brake disc without fasteners, distributing load and reducing wear by residing within the drive slot and engaging with the rotor drive key, thereby minimizing direct contact and stress concentrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If rotor drive keys directly engage with drive slots in the brake disc, then torque transmission is achieved, but mechanical stresses concentrate on the brake disc causing wear and potential rivet failure
Solution Approach 1:
The drive insert acts as an intermediary component between the rotor drive key and the brake disc drive slot. It distributes the mechanical stresses from the drive key across a larger area of the brake disc, preventing stress concentration that would lead to wear and rivet failure. The insert includes a body portion that contacts the drive key and extends into the drive slot, with load-distributing features that spread forces throughout the brake disc material.
2Strength
If fasteners such as rivets are used to attach the drive insert to the brake disc, then secure attachment is achieved, but the fasteners themselves become subject to failure under mechanical stress
Solution Approach 1:
The invention extracts and eliminates the fasteners (rivets, bolts, or other penetrating fastening elements) from the attachment mechanism. Instead of using fasteners that penetrate and potentially fail under stress, the drive insert is retained on the brake disc through interference fits, friction, or mechanical interlocking features that distribute loads without concentrated stress points on individual fasteners.
3Ease of operation
If a simple clip design is used to retain the drive insert, then ease of installation is improved, but secure retention under braking forces may be compromised
Solution Approach 1:
The retention mechanism is segmented into multiple functional elements within the clip design. The clip includes resilient arms or fingers that can be independently deflected during installation and then engage with corresponding features on the brake disc. This segmentation allows the clip to be easily installed by simple snapping or clipping actions while providing strong retention through multiple distributed engagement points that collectively resist braking forces.
Data Source
AI summary
In some examples, a drive insert comprises a clip and a retainer. The clip is configured to be slidable over a surface adjacent to a drive slot of a brake disc in a tangential direction of the brake disc. The retainer is configured to be slidable over the clip when the clip is positioned over the surface to secure the clip to the brake disc. In some examples, the clip may comprise a body section and first and second arms extending from the body section. The retainer may comprise first and second legs configured to contact the first arm and the second arm of the clip when the retainer is positioned over the clip. The first and second legs may be resiliently biased to provide an inward clamping force on the clip when the retainer is positioned over the clip.