Circumferential Disc Brake Layout for Low-Noise Radial Braking

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Solution Overview

Problem

Existing disc brake designs for vehicles suffer from mechanical vibrations, noise generation, brake dust emission, corrosion, non-symmetric pad wear, axial expansion of the caliper housing, uneven thermal loading, excessive heating, and increased weight, which affect brake performance and user experience.

Innovation Solution

A disc brake arrangement featuring a brake disc with radial thermal expansion and a brake pad that contacts the outer circumferential face of the disc, reducing drag torque, noise, and vibrations, while allowing for a smaller, lighter brake disc design with improved wear homogeneity and dust management.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If the brake pad contacts the side face of the brake disc, then the brake force is generated, but mechanical vibrations and noise generation occur

Engineering Contradiction:

Improvebrake forceVSAvoidmechanical vibrations and noise

Core Design Contradiction:

PowerVSObject-affected harmful factors

Solution Approach 1:

Instead of contacting the brake disc at its side faces (conventional design), the brake pad is configured to contact the outer circumferential face of the brake disc. This inverted contact geometry transforms the braking mechanism from axial contact to radial contact, thereby generating brake force while significantly reducing mechanical vibrations and noise generation.

Inventive Principle:

Principle #13The other way round (Inversion)

2Power

If the brake disc is axially clamped between two brake pads, then the brake force is generated, but brake dust emission increases

Engineering Contradiction:

Improvebrake forceVSAvoidbrake dust emission

Core Design Contradiction:

PowerVSObject-generated harmful factors

Solution Approach 1:

The contact surface is inverted from the side face to the outer circumferential face. This configuration changes the direction of frictional force generation and brake dust production, allowing for better containment and management of brake dust emissions while maintaining effective braking performance.

Inventive Principle:

Principle #13The other way round (Inversion)

3Power

If the brake pad contacts the side face of the brake disc, then the brake force is generated, but corrosion of the brake disc occurs

Engineering Contradiction:

Improvebrake forceVSAvoidcorrosion

Core Design Contradiction:

PowerVSObject-affected harmful factors

Solution Approach 1:

By contacting the outer circumferential face instead of the side face, the brake pad avoids direct axial contact with the brake disc's side surfaces. This inversion protects the side faces from corrosive effects of friction and heat while still enabling effective brake force generation through radial contact.

Inventive Principle:

Principle #13The other way round (Inversion)

4Power

If the brake pad contacts the side face of the brake disc, then the brake force is generated, but non-symmetric pad wear occurs

Engineering Contradiction:

Improvebrake forceVSAvoidpad wear symmetry

Core Design Contradiction:

PowerVSManufacturing precision

Solution Approach 1:

The contact geometry is inverted from axial side-face contact to radial outer-circumferential contact. This configuration promotes more uniform distribution of contact pressure and friction forces across the brake pad surface, resulting in more symmetric and homogeneous wear patterns while maintaining effective braking.

Inventive Principle:

Principle #13The other way round (Inversion)

5Power

If the brake caliper housing is subjected to high pressure, then the brake force is generated, but axial expansion of the caliper housing occurs

Engineering Contradiction:

Improvebrake forceVSAvoidaxial expansion

Core Design Contradiction:

PowerVSObject-affected harmful factors

Solution Approach 1:

By generating brake force through radial contact at the outer circumferential face rather than axial contact, the direction of force transmission is changed. This reduces the axial pressure component acting on the caliper housing, thereby minimizing axial expansion while still achieving the required brake force.

Inventive Principle:

Principle #13The other way round (Inversion)

6Power

If the brake disc is subjected to unequal thermal loading, then the brake force is generated, but coning of the brake disc occurs

Engineering Contradiction:

Improvebrake forceVSAvoiddisc coning

Core Design Contradiction:

PowerVSShape

Solution Approach 1:

The contact point is inverted from the side face to the outer circumferential face, which changes the thermal loading pattern. This configuration promotes more uniform heat distribution across the brake disc by avoiding concentrated axial heating at the side faces, thereby reducing thermal gradients that cause disc coning.

Inventive Principle:

Principle #13The other way round (Inversion)

7Power

If the brake disc size is increased, then the braking performance is improved, but the weight of the brake system increases

Engineering Contradiction:

Improvebraking performanceVSAvoidbrake system weight

Core Design Contradiction:

PowerVSWeight of moving object

Solution Approach 1:

The contact geometry is inverted to utilize the outer circumferential face for braking. This configuration allows for more efficient use of the brake disc's braking surface area, enabling effective braking performance with a smaller, lighter brake disc design compared to conventional side-face contact systems.

Inventive Principle:

Principle #13The other way round (Inversion)

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 reduces drag torque, noise, and vibrations, enhances brake performance by maintaining effective braking radius with reduced size and weight, and improves wear uniformity and dust management, addressing the drawbacks of existing disc brake designs.

Implementation Method 1

at least one brake pad (14) having a brake lining (28) and being movable to contact the outer circumferential face (24) of the brake disc (12) for generating a brake force

Methodology Applied

Scientific EffectFriction: Friction

Implementation Method 2

a brake disc (12) configured to expand thermally in a radial direction about a rotational axis (R)

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS20230279912A1Disc brake arrangement having a circumferentially contacted brake disc

Publication Date: 2023.09.07 HL MANDO CORP

AI summary

The invention concerns a disc brake arrangement for a vehicle, in particular a road vehicle, comprising: a brake disc that is rotatable about a rotation axis; at least one brake pad having a brake lining and being movable to contact an outer circumferential face of the brake disc for generating a brake force.