Multi-Part Brake Rotor With Positive-Locking Torque Transfer
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Solution Overview
Problem
Existing multi-part brake rotors for utility vehicles experience torque fluctuations leading to potential connection failures due to non-positive locking mechanisms, compromising safety.
Innovation Solution
A brake rotor design featuring a friction element and an adapter element with positively locking engagement between connection and transfer regions, ensuring reliable torque transfer, even under dynamic conditions, through direct or indirect positive locking, and a multi-part adapter element for enhanced damping and thermal decoupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If non-positive locking mechanisms are used to transfer torque between brake rotor components, then manufacturing costs are reduced, but connection reliability deteriorates under dynamic torque fluctuations
Solution Approach 1:
The brake rotor is divided into multiple components (friction element and adapter element) that can be manufactured separately and assembled. The connection region and transfer region are segmented into distinct engagement elements that provide positive locking while allowing for separate manufacturing of components, thus maintaining cost-effectiveness while improving reliability.
Solution Approach 2:
The patent introduces an intermediate engagement structure (connection region with engagement elements) that mediates between the friction element and adapter element. This intermediary mechanism enables reliable positive locking torque transfer without requiring the entire brake rotor to be manufactured as a single complex piece, balancing manufacturing ease with connection reliability.
2Ease of manufacture
If multi-part brake rotor design is used to reduce manufacturing costs, then manufacturing complexity increases, but torque transfer reliability may deteriorate
Solution Approach 1:
The brake rotor is divided into multiple components (friction element and adapter element) that can be manufactured separately and assembled. The connection region and transfer region are segmented into distinct engagement elements that provide positive locking while allowing for separate manufacturing of components, thus maintaining cost-effectiveness while improving reliability.
Solution Approach 2:
The adapter element serves multiple functions: it provides the installation region for mounting to the hub, contains the transfer region for torque transfer, and incorporates the positive locking engagement mechanism. This multi-functionality reduces the need for additional separate components, thereby controlling structural complexity while maintaining manufacturing advantages.
3Reliability
If positive locking engagement is implemented for reliable torque transfer, then connection reliability improves, but device complexity increases
Solution Approach 1:
The patent introduces an intermediate engagement structure (connection region with engagement elements) that mediates between the friction element and adapter element. This intermediary mechanism enables reliable positive locking torque transfer without requiring the entire brake rotor to be manufactured as a single complex piece, balancing manufacturing ease with connection reliability.
Solution Approach 2:
The brake rotor is divided into multiple components (friction element and adapter element) that can be manufactured separately and assembled. The connection region and transfer region are segmented into distinct engagement elements that provide positive locking while allowing for separate manufacturing of components, thus maintaining cost-effectiveness while improving reliability.
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 design achieves a high level of safety by reliably transferring torque, minimizing the risk of connection failures, and providing efficient thermal decoupling and damping, while maintaining a compact and cost-effective structure.
Implementation Method 1
the connection region indirectly or directly engages in positively locking fashion in a circumferential direction with the transfer region such that a torque about the axis of rotation can be transferred between the connection region and the transfer region
Implementation Method 2
The friction element of the brake rotor is designed to come into contact with a further element—such as for example a brake pad—in order to generate a braking torque
Implementation Method 3
a multi-part adapter element for enhanced damping and thermal decoupling
Data Source
AI summary
A brake rotor, includes at least one friction element and one adapter element, wherein the brake rotor is configured to rotate about an axis of rotation, wherein the friction element has at least one friction surface and one connection region, wherein the adapter element has an installation region and a transfer region, wherein the installation region is configured for fixing the brake rotor to a hub, wherein the connection region indirectly or directly engages in positively locking fashion in a circumferential direction with the transfer region such that a torque about the axis of rotation can be transferred between the connection region and the transfer region from the friction element to the adapter element.