Brake Disc Rotor Bracket Integration via Projections

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Solution Overview

Problem

Conventional brake discs integrate the rotor and bracket via fastening means, resulting in increased weight and a larger number of components, limiting the selection of optimum materials and complicating the manufacturing process.

Innovation Solution

A manufacturing method that processes a rotor with inwardly projecting projections and a tubular bracket with corresponding openings, integrating them by inserting the bracket through the rotor's center hole and fitting the projections into the openings, optionally using diameter reduction or enlargement processing and swaging to secure the components without fastening means.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the rotor and bracket are integrated by fastening means, then the materials of rotor and bracket can be selected separately, but the weight of the brake disc increases and the number of components increases

Engineering Contradiction:

Improvematerial selectionVSAvoidbrake disc weight

Core Design Contradiction:

Adaptability or versatilityVSWeight of moving object

Solution Approach 1:

The rotor and bracket are merged into a single integrated component through direct formation or casting processes. The bracket is formed as an integral part of the rotor, eliminating the need for separate fastening means while maintaining the ability to select different materials for different regions through material-specific manufacturing processes

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The fastening means (fasteners, rivets, bolts) are extracted or removed from the design entirely. The connection between rotor and bracket is achieved through direct structural integration rather than mechanical fastening, thereby eliminating the additional weight and component count associated with fastening elements

Inventive Principle:

Principle #2Taking out (Extraction)

2Adaptability or versatility

If the rotor and bracket are integrated by fastening means, then the materials of rotor and bracket can be selected separately, but the number of components increases

Engineering Contradiction:

Improvematerial selectionVSAvoidnumber of components

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated rotor-bracket structure serves multiple functions simultaneously: the rotor provides braking surface functionality while the integrated bracket provides mounting and structural support. This multi-functionality is achieved within a single component, reducing the overall component count while maintaining material selection flexibility

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Device complexity

If projections are fitted into openings to integrate rotor and bracket, then fastening means are eliminated, but additional processing steps are required

Engineering Contradiction:

Improvenumber of componentsVSAvoidmanufacturing process

Core Design Contradiction:

Device complexityVSEase of manufacture

Solution Approach 1:

The projections on the rotor and corresponding openings in the bracket are pre-formed during the initial manufacturing process (forming or casting). This preliminary action ensures that the integration features are already in place before assembly, eliminating the need for additional fastening steps and simplifying the overall manufacturing process

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The projections and openings are designed to self-align and self-secure during assembly. The geometric configuration of the projections fitting into the openings provides automatic positioning and locking, eliminating the need for external fastening means or complex alignment procedures

Inventive Principle:

Principle #25Self-service

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

This method allows for the selection of optimal materials for the rotor and bracket, reducing the brake disc's weight and component count, while ensuring a firm integration and eliminating the need for fastening means, thereby simplifying the manufacturing process and enhancing strength and heat resistance.

Implementation Method 1

enlarging the diameter of the bracket via outwardly deforming at least the region in which said openings are formed

Methodology Applied

Scientific EffectPlastic deformation: Plasticity

Implementation Method 2

said integrating step carries out a swaging step of integrating said bracket with the rotor by swaging said projections into said openings

Methodology Applied

Scientific EffectSwaging: Plasticity

Data Source

PatentEP3169911B1A brake disc and the manufacturing method thereof

Publication Date: 2019.11.20 FRENI BREMBO SPA

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AI summary

A manufacturing method of a brake disc, comprising the steps of: processing a rotor (1) to acquire the rotor made of the approximately annular plate material with a center hole, the opening edge of said center hole having a plurality of projections (1b) projecting inwardly; processing a bracket (2) to acquire a bracket made of a tubular member, in which openings (2c) corresponding to the projections (1b) are formed; and integrating the bracket (2) with the rotor (1) by inserting the bracket through the center hole of the rotor acquired by the rotor processing step and fitting the projections of the rotor into the openings of the bracket. A disc brake acquired according to the manufacturing method of the brake disc.