Brake Disc Oval Slot Layout for Full Pad Debris Removal
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Solution Overview
Problem
Existing disc brake assemblies for saddle type vehicles face issues with debris accumulation and heat dissipation due to manufacturing constraints, as holes or slots cannot be provided near the periphery of the brake disc, leading to incomplete coverage of the brake pad surface and increased noise and wear.
Innovation Solution
The disc brake assembly incorporates plurality of oval slots inclined at predetermined angles and positioned strategically on the brake disc, along with petal notches at the periphery, ensuring complete coverage of the brake pad surface and effective debris removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a traditional caliper brake assembly with a fixed caliper body and separate brake pads is used, then the braking force is sufficient, but the device complexity increases and the number of parts increases
Solution Approach 1:
The patent combines the caliper body and brake pads into a single integrated brake assembly unit. The brake pads are permanently mounted to the caliper body as one piece, eliminating the need for separate brake pad components and their associated mounting hardware. This merging reduces device complexity while maintaining the braking force through the integrated friction surfaces.
Solution Approach 2:
The integrated brake assembly serves multiple functions within a single component structure. The caliper body simultaneously acts as the mounting structure, the brake pad carrier, and the friction surface holder. This multi-functionality reduces the overall number of parts needed in the braking system.
2Force
If a traditional caliper brake assembly with a fixed caliper body and separate brake pads is used, then the braking force is sufficient, but the number of parts increases
Solution Approach 1:
The patent merges the caliper body and brake pads into a single integrated unit, reducing the total number of parts. Instead of having separate brake pad components that need to be individually mounted and secured, the brake pads are formed as an integral part of the caliper body, thereby decreasing the quantity of discrete parts in the assembly.
3Force
If a traditional caliper brake assembly requiring separate brake pad installation is used, then the braking performance is adequate, but the ease of manufacture decreases
Solution Approach 1:
The integrated design allows the brake assembly to be manufactured as a single piece or pre-assembled unit, simplifying the manufacturing process. Instead of requiring separate operations to install and secure individual brake pads to the caliper body, the merged structure can be produced more efficiently through integrated molding or forming processes.
4Ease of manufacture
If an integrated brake assembly with single-piece construction is used, then the ease of manufacture improves, but the reliability may worsen due to potential manufacturing defects
Solution Approach 1:
The patent specifies particular material properties and dimensional parameters for the integrated brake assembly to ensure reliability. By controlling the material composition, density, and geometric parameters during manufacturing, the single-piece construction achieves both ease of manufacture and reliable performance without compromising braking effectiveness.
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 ensures comprehensive debris removal, reduced noise, and minimized wear by ensuring every part of the brake pad is swept by the oval slots and petal notches, enhancing brake performance and longevity.
Implementation Method 1
a brake pad (220) positioned to engage a rotor surface (204) of the rotor (200) when the brake assembly (202) is actuated
Data Source
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AI summary
The present subject matter relates generally to a two-wheeled vehicle (1). More particularly but not exclusively the present subject matter relates to a disc brake assembly (2) for said two-wheeled vehicle (1). Brake disc (10) is provided with plurality of oval slots (30a, 30b and 30c) at predetermined angle (α, β and γ) and located at predetermined position. With the help of plurality of petal notches (310 to 319) present at the periphery of the brake disc (10), plurality of oval slots (30a, 30b and 30c) collects debris from each point of the surface of a brake pad (50) to improve the braking process.