Bicycle Brake Disc Shape Coupling Connection Reliability
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Solution Overview
Problem
Bicycle brake discs made in two components face reliability issues due to potential damage or breaking at connection areas, which can compromise braking quality and safety, especially in racing bicycles.
Innovation Solution
The brake disc design incorporates connection arms from the braking track that extend towards the rotation axis and are coupled with radially outer connection portions of a second component through shape couplings, ensuring rotational constraint even if the connection between components is damaged, without requiring additional structural elements like bolts or screws, and includes axial locking members to maintain pressure and friction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the brake disc is made in two components (braking track and spider) to reduce weight, then the weight is reduced, but the connection areas between components become vulnerable to damage or breaking
Solution Approach 1:
The patent applies beforehand cushioning by creating shape couplings between connection arms and radially outer connection portions that can absorb and accommodate relative movements between the braking track and spider components. These shape couplings act as pre-designed stress relief mechanisms that prevent connection failure under thermal expansion and mechanical loads, thereby maintaining connection reliability while preserving the weight benefits of the two-component design
2Strength
If the connection between first component and second component allows relative radial and axial movement to stop thermal dilations, then thermal stress is reduced, but connection strength and braking quality may be compromised
Solution Approach 1:
The patent applies dynamics by designing the shape couplings to allow controlled relative radial and axial movements between the braking track and spider components. This dynamic capability enables the connection to accommodate thermal expansions and contractions during braking operations, preventing stress accumulation and connection failure while maintaining consistent braking quality through the friction interface
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 design maintains sufficient braking capability even if the connection between components is damaged, allowing for safer operation until the brake disc can be replaced, while enhancing the structural strength and thermal stability of the braking track.
Implementation Method 1
at least one of the connection arms of the first component and at least one of the radially outer connection portions of the second component are coupled together through at least one shape coupling
Implementation Method 2
the pads are brought towards the brake disc, generating friction on the brake disc and, consequently, braking the wheel
Implementation Method 3
Such relative movement is useful to stop the thermal dilations of the first component that occur during use (by the friction generated by the contact between pads and braking track)
Data Source
AI summary
A brake disc having a first component made of a first material, a braking track configured to cooperate with brake pads, and a second component made of a second material and having (i) a radially inner annular portion for coupling with a hub of a bicycle wheel and (ii) a plurality of radially outer portions for connecting to the first component at a respective plurality of connection portions of the first component. The first component comprises a plurality of connection arms that extend from the braking track towards the predetermined rotation axis (X) and that are distinct from the plurality of connection portions, wherein at least one of the connection arms of the first component and at least one of the radially outer connection portions of the second component are coupled together through at least one shape coupling.