Carbon-Fiber Plastic Brake Module for Quiet Vehicle Flap Braking
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Solution Overview
Problem
Existing brake systems for vehicle flap drive systems suffer from noise generation, increased wear, temperature and speed dependency, high cost, and complex installation, particularly in systems using disk brakes, electromagnets, and permanent magnet brakes.
Innovation Solution
A brake module with a one-piece plastic friction partner containing carbon fibers, combined with steel thrust washers, features optimized friction surfaces and a simple design to reduce wear and noise, while being cost-effective and easy to manufacture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If a disk brake with friction partners is used, then braking function is achieved, but noise generation and odor occur
Solution Approach 1:
The brake disk is made from a composite material consisting of plastic and carbon fibers. This composite structure provides effective braking function while being noiseless and odorless, resolving the contradiction between braking reliability and noise generation.
2Force
If traditional friction materials are used, then braking force is achieved, but wear increases and service life decreases
Solution Approach 1:
The combination of plastic and carbon fibers creates a friction material that maintains sufficient braking force while significantly reducing wear. The carbon fibers reinforce the plastic matrix, allowing the brake disk to withstand frictional forces over an extended service life.
3Force
If PTFE is used in brake design, then friction properties are improved, but temperature and speed dependency increases
Solution Approach 1:
The invention changes the material parameters by using carbon fiber-reinforced plastic instead of PTFE. This material composition provides friction properties that are less dependent on temperature and speed variations, improving adaptability across different operating conditions.
4Ease of operation
If electromagnets with friction partners are used, then switchable braking is achieved, but installation complexity and auxiliary power requirements increase
Solution Approach 1:
The invention extracts and removes the electromagnet components from the brake system. The braking function is achieved purely through the friction between the brake disk and friction partners, eliminating the need for auxiliary power and complex installation while maintaining switchable braking capability.
5Reliability
If permanent magnet brakes are used, then non-switchable braking is achieved, but cost increases
Solution Approach 1:
The invention replaces expensive permanent magnet brakes with a simpler, more cost-effective friction-based brake system. The plastic and carbon fiber components can be manufactured using conventional processes, significantly reducing production costs while maintaining reliable braking function.
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 provides a brake module with a long service life, low wear, reduced noise, and cost-effectiveness, ensuring precise control and high positioning accuracy in vehicle flap drive systems.
Implementation Method 1
The carbon fiber content ensures long-lasting, low-wear friction between the friction partners
Data Source
AI summary
The invention relates to a brake module (100) for a vehicle flap drive system with at least one first friction partner (130) and at least one second friction partner (160, 170), wherein the friction partners (130, 160, 170) each have at least one friction surface (140, 150, 180, 190) which rub against one another during braking operation, wherein the first friction partner (130) is formed in one piece from a plastic with a carbon fiber content.The invention further relates to a vehicle flap drive system comprising a brake module (100).