Disc Brake Bell-Band Coupling Without Radial Constraint
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Solution Overview
Problem
Existing disc brake assemblies face challenges with high weight, structural complexity, and reduced cooling efficiency due to complex couplings between the bell and braking band, which also limit the axial dimensions and increase the risk of thermal stress and wear.
Innovation Solution
A disc brake assembly with a bell and braking band connected via axial and tangential constraints, utilizing a driving element that selectively constrains the band in axial and circumferential directions while avoiding radial constraints, allowing for a gasket effect to ensure constant contact and uniform behavior, thus reducing weight and enhancing cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a complex coupling structure is used to connect the bell and braking band with tangential and axial constraints, then the transmission of braking torque is ensured, but the weight and structural complexity of the assembly increases
Solution Approach 1:
The coupling structure is divided into modular components: the bell with its connecting elements (radial extensions with seating surfaces) and the braking band with corresponding connecting elements. This segmentation allows for a simpler, more manageable connection system that reduces overall complexity while maintaining functional integrity.
Solution Approach 2:
The invention transitions from complex multi-directional constraints to a simplified constraint system that primarily operates in axial and tangential dimensions. By using radial extensions that protrude in radial direction and provide seating surfaces, the coupling achieves torque transmission through a more straightforward geometric arrangement that reduces structural complexity.
2Strength
If a complex coupling structure is used to connect the bell and braking band, then the mechanical strength is maintained, but the cooling efficiency of the braking band is reduced
Solution Approach 1:
The invention extracts the essential coupling function from the complex structure, isolating only the necessary constraint elements (radial extensions with seating surfaces for axial and tangential constraints). This removal of unnecessary structural elements opens up space for improved air flow and cooling channels, thereby enhancing cooling efficiency while maintaining the required mechanical strength.
Solution Approach 2:
By repositioning the constraint mechanism to use radial extensions that protrude outward, the coupling structure creates additional space within the braking band assembly for cooling channels and air flow paths. This dimensional reorganization allows cooling efficiency to improve without compromising the mechanical strength provided by the constraint system.
3Stability of the object's composition
If the bell and braking band are connected with multiple constraints, then the structural integrity is ensured, but the axial dimensions and weight of the assembly increase
Solution Approach 1:
The coupling system is segmented into distinct functional elements: radial extensions for positioning, seating surfaces for axial constraint, and interlocking features for tangential constraint. This segmentation allows each element to be optimized independently, reducing redundant material and overall weight while maintaining structural integrity through precise, targeted constraints.
Solution Approach 2:
The invention uses radial extensions that protrude in the radial dimension to achieve constraints that would otherwise require additional axial dimension. By utilizing the radial direction for positioning and constraint, the assembly maintains structural integrity without increasing axial dimensions or overall weight, as the constraint mechanism leverages the existing radial geometry of the bell and braking band.
4Stability of the object's composition
If the bell and braking band are connected with multiple constraints, then the structural integrity is ensured, but the axial dimensions and weight of the assembly increase
Solution Approach 1:
The constraint mechanism is designed to primarily utilize radial and tangential dimensions rather than axial dimension. The radial extensions protrude in radial direction and provide seating surfaces that constrain the braking band axially through a compact arrangement, thereby maintaining structural integrity without significantly increasing the overall axial dimensions of the assembly.
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 simplifies the connection between the bell and braking band, reduces the overall dimensions and weight of the assembly, improves cooling efficiency, and maintains structural integrity under thermal stress, addressing the drawbacks of prior art while ensuring accurate connection and safety.
Implementation Method 1
The friction of the pads against the braking band of the disc determines the dissipation of the kinetic energy of the masses to be braked into heat
Implementation Method 2
In order to take the different thermal expansion of the materials and the brittleness of the braking band into account, the bell and the braking band are often coupled by means of a joint with tangential and axial constraints and without any radial constraints so as to allow the different radial expansions of the two pieces due to temperature
Data Source
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AI summary
Disc brake disc assembly adapted to cooperate with a brake caliper for exerting a braking action on a vehicle, said assembly comprising: a braking band (2); - a bell (13) for connecting the disc assembly (1) to a support of a vehicle; - at least one driving element (20); wherein - said bell (13) comprising at least one driving bell surface, and wherein - said bell (13) rests on at least one surface of the braking band (2), or on a plurality of surfaces of the braking band (2) substantially coplanar with one another, thus avoiding a bilateral constraint at least between said bell and said braking band (2); - said braking band (2) comprising at least one driving band surface); - said at least one driving element (20) slidingly rests on said at least one driving band surface; - said at least one driving element (20) is selectively movable along said at least one driving band surface), at least passing: - from a position in which it avoids resting on the bell (13) - to a position in which it rests on the bell and constrains said bell (13) to said band; - thus avoiding said braking band (2) from being constrained to said bell (13) in radial direction; - said band comprises a band edge which forms an outer radial abutment band seat (37) which prevents a movement in radial direction of said driving element (20); and wherein - said at least one driving element comprises at least one radial driving element extension; and wherein - said radial driving element extension comprises a coupling tooth (38) which is at least partially and removably inserted into said outer radial abutment band seat (37).