Composite Brake Disc Spring Element for Pressure Distribution
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Solution Overview
Problem
Existing brake disc designs face challenges in minimizing surface pressure on ceramic materials during brake operation to prevent damage, while also simplifying assembly and achieving effective axial damping and radial play adjustment.
Innovation Solution
A composite brake disc design featuring a spring element with alternating steps and recesses, secured by screws, which distributes pressure evenly and allows adjustable deformation, eliminating thrust in the circumferential direction and reducing the need for multiple resilient parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple resilient parts (spring washers, disc springs) are used to fasten the friction ring to the pot, then the braking performance is improved, but the assembly complexity increases and the number of parts increases
Solution Approach 1:
The patent combines multiple resilient parts (spring washers and disc springs) into a single integrated spring element. This spring element has a circumferential spring section and a radial spring section that work together to provide both the axial prestressing force and the necessary compliance, eliminating the need for separate resilient components while maintaining braking performance
Solution Approach 2:
The single spring element performs multiple functions simultaneously: it provides axial prestressing force to clamp the friction ring to the pot, absorbs thermal expansion differences between materials, accommodates manufacturing tolerances, and provides radial compliance. This multi-functional design replaces what previously required multiple specialized components
2Object-affected harmful factors
If the contact surface of spring washers is designed to distribute pressure, then ceramic material damage is prevented, but the surface pressure reduction is insufficient when using aluminum brake disc pots
Solution Approach 1:
The spring element introduces a radial dimension to pressure distribution through its radial spring section. This radial compliance allows the spring to deform outward, distributing pressure not only axially across the friction ring interface but also radially across a larger contact area, significantly reducing peak surface pressures on both ceramic and aluminum materials
Solution Approach 2:
The spring element's material thickness and design parameters can be adjusted to control the degree of radial deformation and pressure distribution. By changing these parameters, the system can optimize pressure distribution for different pot materials (aluminum vs. cast iron) and operating conditions, ensuring adequate pressure reduction to prevent material damage
3Reliability
If prestressed shims are used to increase pressure surface, then the fastening reliability is improved, but the assembly complexity and number of resilient parts increases
Solution Approach 1:
The spring element integrates the functions of prestressed shims and other resilient components into a single unified structure. The circumferential spring section provides the prestressing action equivalent to shims, while the radial spring section adds compliance, eliminating the need for multiple separate resilient parts while maintaining or improving fastening reliability
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 simplifies assembly, reduces surface pressure, enhances axial damping, and allows adjustable radial play, improving braking comfort and enabling tailored spring force for specific vehicle use, while preventing ceramic material damage.
Implementation Method 1
a radial play due to resilient deformation of the spring ring in the radial direction
Implementation Method 2
effective axial damping of the composite brake disc
Data Source
Figure 1
Figure 2~3
AI summary
Spring elements with steps (11,12') for composite brake discs (2,3), which can also be designed as spring rings.