Carbon-Friction Brake Module for Stable Braking Force
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Solution Overview
Problem
Existing brake modules for drive systems, particularly in vehicles, suffer from inconsistent and temperature-dependent braking forces, leading to reduced service life and operational reliability.
Innovation Solution
A brake module comprising a brake disc and thrust washer with friction surfaces coated with a carbon fiber fabric friction layer, which provides a more consistent and predictable braking force, reduces temperature dependence, and extends service life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional friction materials (sintered steel for brake disc and nitrided chromium steel for thrust washer) are used, then the brake module can be manufactured with standard materials and processes, but the braking force is not constant over service life and is temperature-dependent
Solution Approach 1:
The brake disc is constructed as a composite component with a metal substrate providing structural integrity and a ceramic friction layer providing stable friction characteristics. This composite structure combines the advantages of different materials to achieve constant braking force while maintaining manufacturability through established composite material processing techniques
Solution Approach 2:
The invention changes the material parameters of the friction surfaces by introducing ceramic-based friction layers with specifically controlled composition and properties. This parameter change enables temperature-independent friction characteristics and constant braking force throughout the service life, resolving the reliability issue
2Reliability
If conventional friction materials are used, then the brake module structure remains simple, but tolerance compensation is required due to varying braking force
Solution Approach 1:
The ceramic friction layer on the metal substrate provides consistent friction properties that eliminate the need for tolerance compensation. The composite material's stable characteristics ensure predictable braking force, reducing manufacturing precision requirements while improving reliability
3Duration of action of stationary object
If the friction surfaces are made from standard materials, then the brake module can be produced cost-effectively, but the service life is reduced due to wear and temperature effects
Solution Approach 1:
The ceramic friction layer provides superior wear resistance and temperature stability, significantly extending the service life of the brake module. The metal substrate maintains structural integrity, and together they form a durable composite component that can be manufactured using established processes
Solution Approach 2:
The friction layer is designed as a replaceable wear component that protects the more valuable metal substrate. When the friction layer wears, only this layer needs replacement rather than the entire brake disc, extending overall system service life while maintaining manufacturing simplicity
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 brake module achieves a more constant braking force over its service life, is less sensitive to temperature variations, and requires less tolerance compensation, resulting in improved operational reliability and longer service life.
Implementation Method 1
the at least one thrust disc and the at least one brake disc each have at least one friction surface which rub against one another during braking operation
Implementation Method 2
The brake module can comprise a spring that presses the brake disc against the at least one thrust washer using a spring force
Data Source
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AI summary
The invention relates, on the one hand, to a brake module (1) for a drive system, in particular for doors, comprising at least one thrust washer (6) and at least one brake disc (5), wherein the at least one thrust washer (6) and the at least one brake disc (5) each have at least one friction surface that rubs against each other during braking operation. The invention further relates to a drive system, in particular for doors, comprising such a brake module (1). The invention also relates to a manufacturing method for a brake module (1) of the type mentioned above. Known brake modules exhibit a high degree of variation in braking force, both over their service life and depending on the temperature. Therefore, the braking force of the brake module is not well-defined and must regularly be chosen to be higher than desirable in order to ensure the functionality of the brake module.The object of the invention is therefore to provide a brake module that delivers a more constant braking force. According to the invention, this object is achieved by forming at least one of the friction surfaces with a friction layer (20) to protect the brake disc (5) and/or thrust washer (6) from wear, wherein the friction layer (20) comprises fibers and/or carbon. This results in a more constant braking force of the brake module over its service life and reduces temperature dependence. At the same time, the service life of the brake module is increased.