Brake Disc Pad-Carrier Interlock for Efficient Torque Transfer
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Solution Overview
Problem
Existing brake systems face challenges in efficiently transferring torque from rotating rotor discs to stationary stator discs, leading to inefficiencies in braking performance.
Innovation Solution
The brake disc system incorporates a lining carrier with protrusions and recesses in the friction pad, allowing for effective torque transfer between rotating and stationary discs through the interaction of protrusions and recess boundaries, minimizing shear forces on fasteners and reducing exposure to the surrounding environment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the friction pad is directly coupled to the lining carrier using fasteners, then the friction pad is securely attached to the lining carrier, but the fasteners are subjected to high shear forces during torque transfer
Solution Approach 1:
The patent introduces an intermediary mechanical coupling mechanism between the friction pad and lining carrier that transfers torque through geometric interlocking (protrusion-recess interface) rather than relying solely on fastener shear strength. This intermediary structure distributes and redirects the torque transfer path, reducing the shear load on fasteners while maintaining secure attachment.
2Productivity
If the friction pad is extensively coupled to the lining carrier, then torque transfer is efficient, but the friction pad is exposed to more of the surrounding environment
Solution Approach 1:
The patent segments the coupling interface between the friction pad and lining carrier into discrete localized features (protrusions and recesses) rather than using a continuous extensive coupling. This segmentation allows torque transfer to occur through specific concentrated contact points, maintaining efficiency while leaving other portions of the friction pad less exposed to the environment.
3Object-affected harmful factors
If the friction pad is minimally coupled to the lining carrier, then the friction pad is less exposed to the surrounding environment, but torque transfer efficiency decreases
Solution Approach 1:
The patent applies local quality by concentrating the coupling features (protrusions and recesses) at specific strategic locations on the friction pad where they can effectively transfer torque. This localized coupling approach minimizes overall environmental exposure while maintaining adequate torque transfer efficiency through optimized placement and geometry of the coupling features.
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 enhances torque transfer efficiency and reduces oxidation of the friction pad, thereby improving braking performance and durability.
Implementation Method 1
the recess boundary is configured to transfer a torque around the disc axis from the friction pad to the protrusion when the protrusion is inserted in the recess and the torque is imparted to the friction pad
Implementation Method 2
the friction pad is configured to experience a torque around the disc axis when the brake disc rotates relative to an adjacent brake disc and the friction pad engages a friction surface of the adjacent brake disc
Data Source
AI summary
In some examples, a brake disc includes a lining carrier and a friction pad covering a carrier surface of the lining carrier. The lining carrier defines a recess configured to receive a protrusion extending from the carrier surface when the friction pad covers the carrier surface. The friction pad is configured to transfer a torque to the lining carrier via the protrusion when a friction surface of brake disc engages an adjacent brake disc during a braking operation of a brake assembly. In examples, the brake disc includes a fastener configured to couple the lining carrier and the friction pad.