Replaceable Brake Disc Plates With Inclined Ledge Retention

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Solution Overview

Problem

Existing brake disc designs for heavy-duty vehicles face challenges with wear and maintenance, particularly due to the use of screws or bolts that wear down and complicate the replacement of disc plates, leading to uneven brake pad wear and reduced structural integrity.

Innovation Solution

A brake disc design featuring a central disc body with inclined ledges and an enveloping sleeve that secures the disc plates without using screws or bolts, allowing for easy replacement of worn disc plates and reducing wear on brake pads.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If screws or bolts are used to secure disc plates to the central disc body, then the disc plates can be fixed in place, but the screws or bolts become worn and deteriorated due to wear from brake pad contact, reducing structural integrity and complicating replacement

Engineering Contradiction:

Improvestructural integrityVSAvoidscrew and bolt durability

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The invention extracts and removes the screws or bolts from the system by replacing them with an integrated ledge structure formed directly on the central disc body. The ledge provides the necessary securing function without requiring separate fastening elements that would be subject to wear and deterioration.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The ledge is merged with the central disc body as an integrated structure, combining the functions of the central disc body and the fastening element into a single component. This eliminates the need for separate screws or bolts and their associated wear problems.

Inventive Principle:

Principle #5Merging (Combining)

2Ease of repair

If screws or bolts are used to secure disc plates, then the disc plates can be replaced, but the heads of the screws or bolts become worn making unscrewing and replacement quite a challenge

Engineering Contradiction:

Improvedisc plate replacementVSAvoidunscrewing difficulty

Core Design Contradiction:

Ease of repairVSEase of operation

Solution Approach 1:

The invention extracts the problematic screw or bolt heads from the system and replaces them with a ledge structure that can be accessed and operated on from the rear of the central disc body, away from the wear zone of the brake pads.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Instead of accessing the fastening elements from the front (wear side) of the disc plate, the ledge structure is designed to be accessed and operated on from the rear (non-wear side) of the central disc body, inverting the access direction to avoid wear-related difficulties.

Inventive Principle:

Principle #13The other way round (Inversion)

3Strength

If screws or bolts are used to secure disc plates, then the disc plates can be fixed, but the presence of screws or bolts adds to the uneven wear of the brake pads

Engineering Contradiction:

Improvedisc plate fixationVSAvoiduneven brake pad wear

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

The invention extracts the screws or bolts that cause uneven brake pad wear and replaces them with a ledge structure that secures the disc plate without protruding into the brake pad contact area, thereby eliminating the source of uneven wear.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The ledge structure is positioned locally on the central disc body in a location that does not interfere with the brake pad contact area, providing the necessary fixation function while maintaining uniform brake pad wear across the contact surface.

Inventive Principle:

Principle #3Local quality

4Reliability

If the entire brake disc is replaced when disc plates wear out, then the braking function is restored, but unnecessary material is discarded and replacement cost and time increase

Engineering Contradiction:

Improvebraking functionVSAvoiddisc plate material

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The brake disc system is segmented into a permanent central disc body and replaceable disc plates. This allows only the worn disc plates to be replaced while retaining the functional central disc body, reducing material waste and replacement cost.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention enables selective discarding of only the worn disc plates while recovering and reusing the central disc body, which retains its structural integrity and functional value. This partial replacement approach reduces overall material loss.

Inventive Principle:

Principle #34Discarding and recovering

Data Source

PatentUS12203518B2Brake disc and a vehicle

Publication Date: 2025.01.21 VOLVO TRUCK CORP

AI summary

A brake disc configured to be connected to a vehicle axle and to be squeezed between brake pads, comprising a central disc body (30), first and second disc plates (36, 38) releasably securable to the central disc body. Each disc plate has a wear surface and a disc body facing surface. The brake disc has a geometrical centre axis. Each disc plate has an inner periphery and an outer periphery extending from the wear surface to the disc body facing surface. A first ledge (60) mates with the inner periphery of the first disc plate, and a second ledge (60) mates with the inner periphery of the second disc plate. Each ledge comprises at least a ledge portion which is inclined relative to the geometrical centre axis for counteracting axial movement of the disc plates relative to the central disc body.