Brake Disk Rivet Centering and Heat Insulation
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Solution Overview
Problem
Existing brake disks face challenges in minimizing space requirements for attachment to the wheel hub while maintaining low stress levels during braking and effectively transmitting high braking forces, with conventional designs often leading to undesirable friction-ring deformation and heat insulation issues.
Innovation Solution
A brake disk design featuring a brake-disk hub with reduced-wall-thickness portions and axially directed material cutouts for rivet placement, centering the friction ring and hub exclusively via rivets, and an internally ventilated structure with cooling channels and optimized rivet geometry to enhance heat insulation and force transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the brake-disk hub has a solid structure without reduced-wall-thickness portions, then the structural strength is high, but the space required for attaching the brake disk to the wheel hub increases and stress levels during braking increase
Solution Approach 1:
The brake-disk hub is segmented into regions of different wall thicknesses, with reduced-wall-thickness portions (cutouts) strategically positioned to reduce volume and attachment space while maintaining structural integrity through the distributed reinforcement of rivet connection points
Solution Approach 2:
The brake-disk hub exhibits non-uniform wall thickness distribution, with thicker regions providing structural strength and thinner regions reducing overall volume and attachment space requirements, optimizing both strength and space efficiency
2Force
If the friction ring is rigidly connected to the brake-disk hub, then the force transmission is high, but the friction ring deformation under thermal stress increases
Solution Approach 1:
The connection between the friction ring and brake-disk hub allows for controlled movement and deformation through the rivet connections and radial play, enabling the friction ring to dynamically adjust to thermal expansion and contraction while maintaining force transmission capability
Solution Approach 2:
The connection design incorporates radial play and flexible mounting that allows the friction ring to change its dimensional parameters in response to thermal stress, preventing deformation while maintaining effective braking force transmission
3Ease of manufacture
If conventional connection methods are used between friction ring and brake-disk hub, then the manufacturing is simple, but the stress buildup during braking operation increases
Solution Approach 1:
The connection system uses multiple distributed rivet connections instead of a single rigid connection, segmenting the stress distribution across multiple points and reducing peak stress levels while maintaining manufacturing simplicity
Solution Approach 2:
The rivet connections act as intermediaries between the friction ring and brake-disk hub, providing a compliant connection that reduces stress buildup while maintaining force transmission and allowing for straightforward manufacturing
4Force
If the brake-disk hub and friction ring are tightly connected, then the braking force transmission is high, but the heat insulation between components decreases
Solution Approach 1:
The connection interface is segmented into discrete rivet connection points rather than a continuous tight connection, creating thermal barriers between the friction ring and brake-disk hub that reduce heat transfer while maintaining mechanical force transmission capability
Solution Approach 2:
The rivet connections serve as intermediary elements that mechanically couple the friction ring to the brake-disk hub for force transmission while simultaneously providing thermal insulation due to the discontinuous nature of the connection and the presence of radial play
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 minimizes stress and warping, allows for efficient heat dissipation, and enables high braking force transmission while reducing dirt accumulation and maintaining a clean connection, thus optimizing the contact pattern and service life of the brake disk.
Implementation Method 1
channels or bores which have air flowing through them in order thus to improve the dissipation of heat from the friction ring
Implementation Method 2
dissipate the kinetic energy of the motor vehicle in the form of friction heat
Implementation Method 3
the friction ring and the brake-disk hub are centered in relation to one another exclusively via the rivets
Implementation Method 4
This brake-disk hub therefore has a certain elasticity which is beneficial for essentially unimpeded thermal friction-ring expansion
Implementation Method 5
the friction ring is brought into tribological contact with the brake pads of the braking system during braking operation. This dissipates the kinetic energy of the motor vehicle in the form of friction heat
Data Source
AI summary
A brake disk for a disk brake, which consists of a brake disk chamber and at least one friction ring connected to the brake disk chamber by rivets, wherein a jacket of the brake disk chamber is provided with sections having reduced wall thickness and/or through-holes, which are axially directed material cut-outs located on the outer periphery of the brake disk chamber jacket, which material cut-outs are used to at least partially place the axially directed rivets. The friction ring and the brake disk chamber are centered with respect to each other exclusively by the rivets. The friction ring has at least one fastening extension directed inward from the friction surface, to which fastening extension a collar of the brake disk chamber jacket is connected by the rivets in that the side of the friction ring directed toward the brake disk chamber has an axially directed depression for accommodating the collar of the brake disk chamber, which depression is designed in such a way that there is radial play between the brake disk chamber and the friction ring.