Disc Brake Connecting Seat With Jammed Bushings for Lightweight Strength
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Solution Overview
Problem
Conventional disc brake connecting structures are heavy due to iron bolts, which is a disadvantage for lightweight vehicles like electric vehicles that require both light weight and strong connections.
Innovation Solution
A connecting seat for disc brakes comprising a main body made of lighter material like aluminum alloy and bushings with higher hardness and density, such as iron, which are fixedly jammed in through holes to prevent rotation and provide strong, threaded connections without thread tripping, allowing for both light weight and high connecting strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If iron bolts are used to fasten the connecting seat, then connecting strength is improved, but weight increases
Solution Approach 1:
The connecting seat is segmented into different functional parts with different materials: the main body uses lightweight aluminum alloy while the bushings use high-strength iron. This segmentation allows each part to be optimized for its specific function - weight reduction or strength provision.
Solution Approach 2:
Different parts of the connecting seat have different material properties tailored to their local requirements. The bushings located at bolt insertion points use high-hardness iron to prevent thread tripping under high fastening forces, while the main body uses lightweight aluminum alloy for weight reduction.
2Weight of moving object
If aluminum alloy is used for the main body, then weight is reduced, but hardness decreases leading to thread tripping
Solution Approach 1:
The iron bushings act as intermediaries between the aluminum alloy main body and the fastening bolts. These bushings transfer the high fastening forces from the bolts to the main body, protecting the softer aluminum alloy threads from tripping while allowing the main body to remain lightweight.
Solution Approach 2:
The connecting seat uses a composite construction combining aluminum alloy and iron materials. The aluminum alloy provides lightweight structure while the iron bushings provide localized high-strength threading capability, creating a composite component that achieves both weight reduction and sufficient thread strength.
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 achieves a balance between light weight and strong connections by using lighter materials for the main body and denser materials for the bushings, preventing thread tripping and ensuring secure attachment to the caliper device and suspension system.
Implementation Method 1
The bushings are fixedly jammed in the through holes of the main body respectively
Implementation Method 2
the threaded holes can be prevented from the thread tripping problem resulted from overlarge force for fastening the bolts
Data Source
AI summary
A connecting seat for a disc brake includes a main body and a plurality of bushings. The main body includes a plurality of through holes. The bushings are fixedly jammed in the through holes of the main body respectively. The hardness of the bushings is larger than the hardness of the main body. Each bushing includes a first end surface, a second end surface, and a threaded hole penetrating through the first end surface and the second end surface. As a result, the connecting seat has advantages of light weight and great connecting strength.