Brake Disc Rivet Head Forming for Thin Rotor Hat Connection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing brake discs, particularly in lightweight construction, face challenges in achieving a stable mechanical connection between the friction ring and the brake pot due to the thin material thickness of lightweight brake pots, which limits the effectiveness of recess-based connections and surface contact of rivet heads.
Innovation Solution
The rivet head is deformed to lie flat against the curved surface of the brake pot, ensuring a stable mechanical connection by applying a greater perpendicular force at the edge than at the center, allowing it to rest flat on the brake pot's surface, and using a tool with a rounded surface to facilitate this deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a recess-based connection is used to improve mechanical connection stability, then the connection stability improves, but the material thickness is further reduced which compromises structural integrity
Solution Approach 1:
The solution transitions from a recess-based connection (modifying the brake pot material) to a rivet head deformation connection (modifying the rivet head shape). The rivet head is deformed to conform to the curved surface of the brake pot, creating contact in the radial dimension rather than requiring material removal in the axial dimension.
Solution Approach 2:
The rivet head acts as an intermediary element between the collar and the brake pot. By deforming the rivet head to lie flat against the curved surface, it creates a stable mechanical connection without requiring recesses in the thin brake pot material, thus preserving structural integrity while achieving connection stability.
2Reliability
If the rivet head is deformed to lie flat against the curved surface, then the mechanical connection stability improves, but the manufacturing complexity increases
Solution Approach 1:
The rivet head is pre-formed with a specific geometry (larger diameter at the edge than at the center) before insertion. This preliminary shaping allows the rivet head to naturally conform to the curved surface of the brake pot during deformation, simplifying the overall manufacturing process by preparing the component in advance rather than requiring complex in-situ deformation equipment.
3Reliability
If the rivet head has larger diameter at the edge than at the center, then the surface contact area increases improving connection stability, but the rivet head geometry becomes more complex
Solution Approach 1:
The rivet head is designed with non-uniform geometry, having a larger diameter at the edge than at the center. This local variation in dimensions is specifically tailored to match the curved surface geometry of the brake pot, ensuring maximum contact area at the critical edge region where the curved surface requires greater radial clearance for flat contact.
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 approach provides a stable and secure mechanical connection between the friction ring's collar and the brake pot, enhancing the structural integrity of the brake disc while maintaining the lightweight characteristics of the brake pot material.
Implementation Method 1
the rivet head is deformed in such a way that it rests flat against the bent, curved and/or arc-shaped surface of the brake pot facing away from the collar
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a brake disc comprising a friction ring (101a/b) consisting at least partially of a first material and a brake rotor hat (103) consisting at least partially of a second material that is different from the first material. The friction ring comprises a flange formed in the axial direction, the flange is connected to an edge of the brake rotor hat (103) oriented towards the friction ring, by means of at least one connection element designed as a rivet (102), wherein the rivet heat (102) is in flat contact with the surface (2014) of the brake rotor hat facing away from the flange.