Composite Brake Disc Connecting Assembly for Thermal Deformation Control
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Solution Overview
Problem
Conventional brake discs made of gray cast iron are heavy, prone to deformation under thermal expansion, and have high production costs, making them unsuitable for passenger vehicles and electric automobiles, while composite brake discs with aluminum alloy suffer from poor heat resistance and high complexity.
Innovation Solution
A composite brake disc design using a connecting assembly with a sleeve, spring member, and fastener, featuring a simple structure, light weight, and low cost, utilizing U-shaped clamping slots and fasteners for force transfer and assembly, with components made of materials like steel, iron, aluminum, and carbon fiber.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional gray cast iron brake discs are used, then structural strength is sufficient, but weight is large and deformation under thermal expansion is high
Solution Approach 1:
The brake disc is divided into two separate components: an aluminum alloy brake disc body and a friction ring. The aluminum alloy body provides lightweight properties while the friction ring made of gray cast iron provides sufficient friction and structural strength. This segmentation allows each component to be optimized for its specific function, resolving the contradiction between weight reduction and structural strength maintenance.
Solution Approach 2:
The brake disc uses a composite structure combining aluminum alloy (lightweight, good heat dissipation) and gray cast iron (high strength, good friction characteristics). This composite material approach allows the brake disc to achieve both reduced weight and maintained structural strength by leveraging the complementary properties of different materials.
2Weight of moving object
If composite brake disc with aluminum alloy is used, then weight is reduced, but heat resistance is poor and structure becomes complex
Solution Approach 1:
The brake disc is segmented into an aluminum alloy body and a gray cast iron friction ring. The friction ring, made of heat-resistant gray cast iron, is positioned at the friction interface where high temperatures occur during braking. This segmentation allows the aluminum alloy body to provide lightweight properties while the friction ring provides the necessary heat resistance, resolving the contradiction between weight reduction and heat resistance.
Solution Approach 2:
Different materials are used for different regions of the brake disc based on local requirements. The aluminum alloy is used for the main body where weight reduction is prioritized, while the gray cast iron friction ring is used at the friction interface where heat resistance and friction performance are critical. This local quality approach resolves the contradiction by matching material properties to specific functional requirements.
3Weight of moving object
If existing composite brake disc structure is used, then light weight and NVH requirements are met, but structure is complicated and production cost is high
Solution Approach 1:
The connecting assembly integrates multiple functions into a single component structure. The connecting holes in the friction ring serve dual purposes: they provide structural connection between the aluminum alloy body and friction ring, and they facilitate the assembly process. This merging of functions reduces the number of separate components and simplifies the overall structure, resolving the contradiction between achieving lightweight/NVH requirements and reducing structural complexity.
Solution Approach 2:
The friction ring design incorporates universal features that serve multiple functions. The connecting holes not only provide structural integrity but also serve as assembly features. The friction ring itself provides both friction surface and structural connection functions. This multi-functionality reduces the need for additional specialized components, simplifying the overall structure while maintaining lightweight properties.
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 lightweight, cost-effective brake disc with reduced deformation and noise, ensuring efficient torque transfer and assembly simplicity, while maintaining structural integrity and reducing production variability.
Implementation Method 1
the spring member includes a connecting bridge and a pair of elastic pieces
Implementation Method 2
the pair of U-shaped clamping slots of the sleeve include force transferring surfaces
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A composite brake disc connecting assembly and a composite brake disc. The composite brake disc connecting assembly includes a sleeve (1) and a spring member (2); wherein the sleeve (1) includes an upper pressing plate (101), a lower pressing plate (102) and a connecting column (103); a connecting hole (104) is provided at the center of the connecting column (103), and a pair of U-shaped clamping slots are formed between the upper pressing plate (101), the lower pressing plate (102) and the connecting column (103); and the spring member (2) includes a pair of elastic pieces and a connecting bridge (201). The composite brake disc includes a brake disc hat (4), a friction ring (5) and a plurality of composite brake disc connecting assemblies; wherein the brake disc hat (4) is provided with disc hat notches (401) for mounting spring members (2), the friction ring (5) is provided with mounting holes (505) for accommodating connecting columns (103), and the friction ring (5) is connected to the brake disc hat (4) by fasteners (3) inserted onto the connecting columns (103). The composite brake disc has a simple structure, the friction ring (5) can move radially, reducing the deformation amount of the friction ring and preventing brake judder; the whole assembly process is simple, the number of parts is small, the production cost is reduced, and the sources causing variation during the process are reduced.