Disc Brake Rotor Recess Assembly for Screwless Magnet Attachment
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Solution Overview
Problem
Conventional disc brake rotors face challenges in adjusting mechanical characteristics and maintaining a compact structure while avoiding the complexity of screw connections and ensuring effective attachment of non-metallic parts and magnets for rigidity and rotation sensing.
Innovation Solution
The disc brake rotor design incorporates a hub engagement member, a friction member, and a second member that is at least partly provided on a recess without using a screw connection, allowing for adjustment of mechanical characteristics and compactness, with the option to include non-metallic parts and magnets for rigidity and rotation sensing, and secure attachment through a coupling part in a through hole.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a screw connection is used to attach the second member, then the attachment reliability is improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent replaces the traditional screw connection (mechanical fastening system) with a press-fit arrangement where the second member is directly inserted into a recess of the first member. This eliminates the need for screws, holes, and threading, thereby reducing structural complexity while maintaining attachment reliability through precise dimensional matching and interference fit.
Solution Approach 2:
The patent merges the attachment function into the basic structural components themselves. The recess in the first member and the corresponding protrusion on the second member are integrated directly into the main bodies, eliminating separate fastening components. This consolidation reduces the number of parts and simplifies the overall structure while ensuring reliable attachment.
2Adaptability or versatility
If the second member is made larger in axial dimension, then the mechanical characteristic adjustment capability is improved, but the overall rotor size increases
Solution Approach 1:
The patent applies local quality by concentrating the functional properties of the second member (such as magnetic properties for rotation sensing or non-metallic characteristics for rigidity adjustment) into a compact form factor. Instead of increasing the overall axial dimension, the design optimizes the local material properties and distribution within the available space, allowing mechanical characteristic adjustment without proportionally increasing the rotor's axial size.
Solution Approach 2:
The patent utilizes composite material approaches by allowing the second member to be made of different materials (metallic, non-metallic, or magnetic materials) within the same structural framework. This enables adjustment of mechanical characteristics through material selection rather than dimensional changes, maintaining a compact axial profile while achieving the desired adaptability.
3Strength
If non-metallic parts are added to the second member, then the rigidity adjustment capability is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent employs composite material construction for the second member, combining metallic and non-metallic materials to achieve desired rigidity characteristics. The non-metallic portions can be injection-molded or formed and then integrated with metallic components through the press-fit arrangement, leveraging different manufacturing processes for each material type while maintaining overall manufacturing efficiency.
Solution Approach 2:
The patent segments the second member into distinct functional portions, including non-metallic parts that can be manufactured separately and then assembled. This segmentation allows each portion to be optimized for its specific function and manufactured using the most appropriate process, reducing overall manufacturing complexity compared to creating a monolithic component with mixed material properties.
4Measurement precision
If magnets are integrated into the second member, then the rotation sensing capability is improved, but the device complexity increases
Solution Approach 1:
The patent merges the rotation sensing function directly into the second member by integrating magnets into its structure. This eliminates the need for separate sensors or detection systems, as the magnets themselves serve as the measurement element. The simple press-fit connection allows easy positioning and integration of the magnetic components without adding structural complexity.
Solution Approach 2:
The second member is designed with multi-functionality, serving both as a structural component (providing rigidity adjustment through non-metallic parts) and as a rotation sensing element (through integrated magnets). This universal design approach consolidates multiple functions into a single component, reducing the need for additional separate systems and thereby reducing overall device complexity.
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 enables adjustable mechanical characteristics, compactness, and effective attachment of non-metallic parts and magnets, enhancing the disc brake rotor's rigidity and rotation sensing capabilities while simplifying the structure and reducing weight.
Implementation Method 1
the second member includes at least one of a non-metallic part and a magnet... to sense rotation of the disc brake rotor using the magnet
Data Source
AI summary
A disc brake rotor comprises a hub engagement member, a friction member, a first member, and a second member. The hub engagement member is configured to engage with a hub assembly. The friction member is provided radially outwardly of the hub engagement member with respect to a rotational center axis of the disc brake rotor. The friction member has an axial thickness in an axial direction with respect to the rotational center axis. The first member extends between the hub engagement member and the friction member. The first member includes a recess that has an axial depth in the axial direction. The axial depth is larger than the axial thickness of the friction member. The second member is at least partly provided on the recess without using a screw connection.