Brake Disc Rivet Head Geometry for Thin Brake Pot Attachment
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Solution Overview
Problem
In lightweight brake disk construction, achieving a stable mechanical connection between the friction ring and the brake pot is challenging due to the thin material thickness of the brake pot, which limits the use of recesses for reinforcement, necessitating an alternative method to ensure a secure attachment.
Innovation Solution
A rivet connection is used where the rivet head is subjected to a greater force perpendicularly at its rim than at its center, causing it to rest flatly against the surface of the brake pot, ensuring a stable mechanical connection between the friction ring's collar and the brake pot, particularly effective with lightweight materials like aluminum.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a recess is made in the brake pot to improve the mechanical connection with the connecting element, then the connection stability is improved, but the material thickness is further reduced which weakens the brake pot structure
Solution Approach 1:
The rivet head is designed with a specific geometry where the rim region has higher material density or reinforcement compared to the center, allowing the connection force to be concentrated at the rim where it can effectively engage with the brake pot without requiring a recess that would compromise overall structural strength
Solution Approach 2:
Instead of modifying the brake pot by creating a recess (modifying the object receiving the fastener), the solution modifies the rivet head itself by creating an asymmetric force distribution across its surface. This shifts the problem from modifying the brake pot geometry to modifying the rivet head geometry, thereby avoiding further reduction of brake pot material thickness
2Weight of moving object
If lightweight materials like aluminum are used for the brake pot, then the overall brake disk weight is reduced, but the material thickness must be kept small which complicates the mechanical connection
Solution Approach 1:
The rivet head is designed with specific geometric parameters - an asymmetric force distribution pattern where the rim region is optimized for engagement with thin-walled aluminum brake pots. This parameter optimization allows effective connection without requiring increased material thickness or complex recess geometries, thereby facilitating the use of lightweight materials
Solution Approach 2:
The rivet head design effectively creates a distributed bearing surface pattern that copies the load distribution needs across the thin brake pot material. Rather than requiring a single concentrated connection point that would need a recess, the rivet head distributes the connection function across its rim perimeter, matching the structural capabilities of thin-walled aluminum construction
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 provides a robust and stable mechanical connection without further reducing the thin material thickness of the brake pot, enhancing the structural integrity of the brake disk while allowing for the use of lightweight materials.
Implementation Method 1
the rivet head is subjected to a greater force, acting substantially perpendicularly to the rivet, at its rim than in its center. By means of the force distributed in accordance with the disclosure on the rivet head, a deformation occurs such that the rivet head rests substantially flatly against that surface of the brake pot
Data Source
AI summary
A brake disc includes a friction ring having a first material and a brake rotor hat having a second material that is different from the first material. The friction ring includes a flange formed in the axial direction, and the flange is connected to an edge of the brake rotor hat oriented towards the friction ring, by means of at least one connection element designed as a rivet. The rivet head is in flat contact with the surface of the brake rotor hat facing away from the flange.