Two-Piece Brake Disc Connection Using Radial Pot Deformations
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Solution Overview
Problem
Brake discs designed in multiple parts face instability under high braking stresses, leading to potential damage and thermal distortion due to inadequate connection between the friction ring and brake pot.
Innovation Solution
A brake disc design featuring a side wall deformation in the brake pot to form a non-rotatable connection with the friction ring, maintaining a Da/Di ratio of 1.01 or less, allowing for a stable and weight-reduced structure with enhanced heat dissipation and braking torque transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the brake pot side wall is made oversized relative to the friction ring inner diameter, then the connection stability is improved, but the manufacturing difficulty increases and damage risk rises
Solution Approach 1:
The patent applies parameter changes by precisely controlling the Da/Di ratio to be at most 1.01, optimizing the dimensional relationship between brake pot outer diameter and friction ring inner diameter. This precise parameter control achieves reliable connection without excessive oversizing, avoiding manufacturing difficulties and damage risks while ensuring connection stability under braking loads.
Solution Approach 2:
The patent implements preliminary action by forming deformations in the brake pot side wall before final assembly. These pre-formed deformations create contact surfaces that ensure proper positioning and stable connection, preventing damage during assembly while maintaining manufacturing feasibility through controlled plastic deformation of the side wall.
2Strength
If the brake disc is designed as a single piece, then the structural strength is improved, but the weight increases
Solution Approach 1:
The patent applies segmentation by dividing the brake disc into two separate components: a friction ring and a brake pot. The friction ring can be made from high-strength cast iron materials optimized for friction performance, while the brake pot provides structural support. This segmentation reduces overall weight compared to a single-piece design while maintaining structural strength through optimized material selection and the deformation-based connection mechanism.
3Ease of manufacture
If the friction ring and brake pot are loosely connected, then the manufacturing ease is improved, but the connection stability under braking stress deteriorates
Solution Approach 1:
The patent implements preliminary action by pre-forming deformations in the brake pot side wall that create protrusions or contact surfaces. These pre-formed features guide the friction ring into proper position during assembly and create stable mechanical interlocking, ensuring both easy assembly and reliable connection stability under braking stresses without requiring complex fastening procedures.
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 provides a stable, non-rotatable connection between the friction ring and brake pot, reducing the risk of damage and thermal distortion, while enabling efficient heat dissipation and increased braking torque, suitable for various vehicle types.
Implementation Method 1
a side wall (4) of the brake pot (3) having at least one deformation (5) in the radial direction, via which deformation a contact surface (7) oriented in the circumferential direction of the brake pot is formed, with which contact surface a non-rotatable connection (8) is established between the friction ring (2) and the brake pot (3)
Implementation Method 2
By creating friction between the brake disk and the brake pad, a kinetic energy of a vehicle can be converted into a thermal energy, causing the vehicle to lose speed.
Data Source
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AI summary
The invention relates to a brake disc (1) comprising at least one friction ring (2) and a brake pot (3) connected to the friction ring (2) for conjoint rotation. A side wall section (17) of the brake pot (3) has a plurality of radially oriented deformations (5). A contact surface (7) extending in the radial direction is formed by means of said deformations (5), and a rotationally fixed connection (8) is established by said contact surface (7) between the friction ring (2) and the brake pot (3). A ratio Da/Di formed from the outer diameter Da of a side wall section (17) of the brake pot (3) and an inner diameter Di of the friction ring (2) is at most 1.01.