Dual-Material Brake Rotor Hub Friction Contradiction
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Solution Overview
Problem
Brake rotors made from fiber-reinforced duroplastic materials face issues with high mechanical stress due to low strength in the hub area, despite having high friction values and vibration tendencies, which compromise their performance under mechanical stress.
Innovation Solution
A brake rotor design featuring a central inner area made of fiber-reinforced thermoset with a high-strength material composition and an annular outer area optimized for medium to high friction values, both made from fiber-reinforced duroplastic materials, connected in a materially bonded manner to achieve integral strength and frictional performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the brake rotor is made from fiber-reinforced duroplastic with high friction material composition, then the coefficient of friction is improved, but the strength in the hub area deteriorates under very high mechanical stress
Solution Approach 1:
The brake rotor is designed with different material compositions in different regions: the hub area uses fiber-reinforced duroplastic optimized for high strength and low compressibility to withstand mechanical stress, while the friction area uses material with high friction properties. This local differentiation allows each region to have the specific properties needed for its function, resolving the contradiction between friction coefficient and hub strength.
Solution Approach 2:
The invention uses composite materials with different fiber reinforcements and material compositions in different sections of the brake rotor. The hub section uses a composite formulation prioritizing tensile and compressive strength, while the friction section uses a composite formulation prioritizing friction characteristics. This composite approach enables simultaneous optimization of both strength and friction properties in different regions.
2Object-generated harmful factors
If the friction material has high compressibility and high elongation to reduce vibration, then the coefficient of friction is improved, but the strength under high mechanical stress deteriorates
Solution Approach 1:
The brake rotor applies local quality by using different material formulations in different regions. The hub area uses material with high strength and low compressibility to resist mechanical stress, while the friction area uses material with properties that reduce vibration and provide high friction. This spatial differentiation of material properties resolves the contradiction between vibration reduction and strength maintenance.
3Ease of manufacture
If the brake rotor is designed as an integral structure from common substrate, then the manufacturing simplicity is improved, but the ability to optimize different areas for different functions deteriorates
Solution Approach 1:
The brake rotor is segmented into different functional zones with distinct material compositions: the hub section and the friction section each have optimized material formulations. This segmentation is achieved through a multi-step manufacturing process where different material batches are processed and bonded together. The segmentation enables functional optimization in each area while maintaining manufacturing feasibility through established composite processing techniques.
Solution Approach 2:
The invention employs composite materials with different formulations in different sections of the brake rotor. The hub section uses a composite material optimized for structural strength, while the friction section uses a composite material optimized for friction characteristics. This composite material approach allows functional differentiation across the integral structure, achieving both manufacturing simplicity and functional optimization.
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3A~3B
AI summary
The rotor (10) has a central inner chamber (12) and a circular outer chamber (14) made of different material compositions of fiber reinforced thermosetting plastics. The outer chamber is arranged concentric to the inner chamber and has a brake section (24) with a friction surface, where the chambers are connected with each other. The inner chamber transfers increased torque from the outer chamber to the shaft, where the outer chamber is optimized concerning to tribological characteristics. The compositions contain cellulose fibers and mineral fibers as reinforcing fibers.