Brake Rotor Mounting Arrangement Thermal Decoupling
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Solution Overview
Problem
Existing disc brake systems for commercial vehicles face challenges in transferring high braking forces while minimizing heat transfer to the axle hub, which can damage components and increase manufacturing costs due to metal-to-metal contact and the use of intermediary elements.
Innovation Solution
A disc brake system with a brake rotor featuring a friction ring and a rotor mounting portion with radially inward splines and axial motion limiting features, coupled with mounting plates, bushings, and fasteners, that thermally decouples the brake rotor from the wheel hub, reducing heat transfer and eliminating the need for intermediary elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If metal-to-metal contact is used between brake disc tabs and hub splines to transfer braking forces, then braking force transfer is effective, but heat transfer to the axle hub increases significantly
Solution Approach 1:
The patent introduces an intermediary element (insert or bushing) between the brake disc tabs and hub splines. This intermediary component serves as a thermal barrier that blocks heat transfer from the brake disc to the hub while still allowing mechanical force transfer through friction and engagement surfaces. The intermediary material is selected to have appropriate friction characteristics for force transfer and thermal properties for heat isolation.
2Temperature
If intermediary disc-to-hub elements are used to reduce heat transfer, then heat isolation is improved, but device complexity and manufacturing costs increase
Solution Approach 1:
The patent designs the intermediary element to perform multiple functions simultaneously: it acts as a thermal barrier, a mechanical force transfer medium, a positioning feature, and potentially a wear compensating component. By consolidating these functions into a single integrated component rather than using separate elements for each function, the overall device complexity is reduced while maintaining effective heat isolation.
3Force
If precision machining of spline/tab engagement surfaces is performed to ensure satisfactory braking force transfer, then braking performance is improved, but manufacturing costs increase
Solution Approach 1:
The patent changes the engagement mechanism from requiring high-precision machined metal-to-metal contact to a system that relies on controlled friction and engagement of simpler geometric features. The intermediary element is designed with parameters (friction coefficient, engagement geometry, material properties) that allow adequate braking force transfer without requiring expensive precision machining of the hub and disc mating surfaces.
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
The solution effectively isolates the wheel hub from direct heat transfer, simplifies installation and maintenance, and reduces manufacturing costs by minimizing metal-to-metal contact and the stress on intermediary elements, ensuring reliable and durable braking performance.
Implementation Method 1
thermally decouples the brake rotor from the wheel hub, reducing heat transfer
Data Source
AI summary
A disc brake for a vehicle axle includes a brake rotor, a brake caliper that straddles the brake rotor, a wheel hub, and a plurality of brake rotor mounting elements that couple the brake rotor to the wheel hub. The brake rotor includes a friction ring portion and a rotor mounting portion radially inward of the friction ring portion. The rotor mounting portion is formed on a radially inner circumference of the brake rotor, and includes a plurality of splines extending radially inward toward an axis of rotation of the brake rotor and a radially inward extending axial motion limiting feature disposed between each adjacent pair of the plurality of splines.