Brake Disc Insert Assembly for Tangential Torque Transfer

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Solution Overview

Problem

Existing brake disc systems in vehicle wheel brakes experience mechanical stress and wear due to direct engagement with rotor drive keys and splines during braking operations, leading to potential deformation and reduced durability.

Innovation Solution

An insert assembly is introduced, comprising an insert, a rivet, and a washer, which mechanically couples with the brake disc to allow tangential motion and distribute load, using a rivet slot to prevent deformation and enhance seating against torque faces, and a washer to facilitate orbital riveting without deforming into the rivet slot.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the brake disc directly engages with rotor drive keys during braking operations, then the braking function is achieved, but mechanical stress and wear on the brake disc increase

Engineering Contradiction:

Improvebrake disc durabilityVSAvoidbrake disc mechanical stress resistance

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

An insert is introduced as an intermediary component between the rotor drive key and the brake disc. The insert receives torque from the rotor drive key and transfers it to the brake disc through a rivet connection, preventing direct engagement and reducing mechanical stress and wear on the brake disc while maintaining the braking function

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If the rivet is rigidly fixed to the insert, then the insert is securely attached to the brake disc, but the insert cannot accommodate tangential motion during braking

Engineering Contradiction:

Improveinsert attachment securityVSAvoidinsert tangential motion capability

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The rivet connection is designed to be dynamic rather than rigid. The rivet allows the insert to move tangentially relative to the brake disc while maintaining secure attachment, enabling the insert to accommodate tangential motion during braking operations without compromising the security of the connection

Inventive Principle:

Principle #15Dynamics

3Ease of manufacture

If orbital riveting is performed without a washer, then the riveting process is simpler, but the rivet head deforms into the rivet slot causing defects

Engineering Contradiction:

Improveriveting process simplicityVSAvoidrivet head deformation control

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

A washer is introduced as an intermediary component during the orbital riveting process. The washer is positioned between the rivet head and the insert, preventing the rivet head from deforming into the rivet slot while allowing the riveting process to proceed. This maintains manufacturing precision without significantly complicating the manufacturing process

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS12449009B2Brake disc insert assembly

Publication Date: 2025.10.21 HONEYWELL INTERNATIONAL INC

AI summary

In some examples, an insert assembly includes an insert, a rivet, and a washer configured to position on a brake disc. The insert is configured to position within a disc slot of the brake disc. The rivet shank is configured extend through a washer hole of the washer and a rivet slot of the insert to secure the insert to the brake disc. The washer is configured to be positioned between the insert and a rivet head of the rivet when the rivet shank extends into the brake disc. The rivet slot is configured to allow for the motion of the insert relative to the rivet in the tangential direction when torque is imparted through the disc slot via the insert. In some examples, the rivet is a solid rivet. In some examples, the rivet head is an orbitally riveted head fabricated using an orbital riveting tool.