Damped Brake Rotor with Cavity Insert for Noise Reduction
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Solution Overview
Problem
Brake noise, particularly in high-performance vehicles, is a significant warranty issue and customer dissatisfaction factor due to the noise generated by brake friction linings, which existing technologies have not adequately addressed.
Innovation Solution
A damped brake rotor design featuring a friction disk with a cavity containing an insert and a braze ring, where the insert moves within a groove and is sealed by a braze ring to prevent contact, thereby reducing noise through frictional damping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If high-performance friction linings are used to improve braking performance, then braking efficiency is improved, but brake noise increases
Solution Approach 1:
The patent converts the harmful vibrational energy that causes brake noise into beneficial damping through the insert mechanism. The insert moves within the cavity in response to rotor vibrations, converting mechanical vibration energy into frictional heat energy, thereby reducing brake squeal and noise while maintaining high-performance braking capability
Solution Approach 2:
The patent changes the physical state and parameters of the brake rotor by introducing a cavity with a movable insert. This modifies the rotor's vibrational characteristics and damping properties, allowing the system to absorb and dissipate vibration energy effectively, thus reducing noise without compromising braking performance
2Object-generated harmful factors
If damping structures are added to reduce brake noise, then brake noise is reduced, but device complexity increases
Solution Approach 1:
The patent segments the brake rotor structure by creating a cavity within the rotor disk and placing a separate movable insert within that cavity. This segmentation allows the damping function to be isolated from the main rotor structure, enabling effective noise reduction while maintaining relatively simple manufacturing processes and assembly procedures
Solution Approach 2:
The insert acts as an intermediary element between the rotor vibrations and the damping mechanism. It mediates the interaction by moving within the cavity in response to vibrations and converting that mechanical energy into frictional heat, providing effective damping without requiring complex active control systems or multiple components
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 effectively minimizes brake squeal and noise by converting vibrational energy into heat through friction, providing at least one order of magnitude higher damping across rotor vibration modes, significantly reducing warranty issues and enhancing customer satisfaction.
Implementation Method 1
The design effectively minimizes brake squeal and noise by converting vibrational energy into heat through friction
Data Source
AI summary
A damped brake rotor has at least one friction disk connected to a hat portion. At least one cavity in located in the friction disk. An insert is located within the cavity. A braze ring is located within the cavity and radially outward from the insert. A braze located within the cavity and radially outward from the braze ring.