Disc Brake Energizing Ring Cantilever Coupling
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Solution Overview
Problem
Anti-lock braking systems in vehicles face issues with corrosion, mechanical stress-induced uncoupling, and thermal deformation affecting the disc assembly and energizing ring, leading to signal deterioration and malfunction.
Innovation Solution
A disc assembly where the energizing ring is made of a more corrosion-resistant material, such as stainless steel, with a cantilevered connecting portion that includes axially projecting feet buried in a less corrosion-resistant disc material, providing mechanical and thermal decoupling while maintaining a firm anchorage, and the assembly is co-melted to prevent separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the energizing ring is made from a corrosion-resistant material like stainless steel, then corrosion resistance is improved, but mechanical strength and thermal resistance deteriorate
Solution Approach 1:
The invention uses a composite structure where the energizing ring is made of corrosion-resistant material (stainless steel or aluminum alloy) and the disc is made of mechanically strong material (gray cast iron or spheroidal graphite cast iron). This composite approach allows each component to be optimized for its specific function: the ring for corrosion resistance and the disc for mechanical strength and thermal resistance.
2Reliability
If the energizing ring is securely coupled to the disc, then reliability is improved, but thermal expansion-induced deformation worsens
Solution Approach 1:
The invention segments the coupling system into two functional parts: the energizing ring that remains free to expand thermally, and the anchoring feet that are embedded in the disc. This segmentation allows the ring to move independently with thermal expansion while maintaining secure mechanical attachment through the feet, resolving the conflict between secure coupling and position stability.
Solution Approach 2:
The anchoring feet act as an intermediary element between the energizing ring and the disc. These feet are embedded in the disc material and provide secure mechanical anchoring, while allowing the ring body to remain thermally independent. The feet mediate between the need for secure coupling and the need to accommodate thermal expansion.
3Duration of action of stationary object
If the disc material is made more corrosion-resistant, then durability is improved, but cost and manufacturing complexity worsen
Solution Approach 1:
The invention applies local quality by making only the energizing ring (the component exposed to corrosion) from corrosion-resistant material, while the disc body can be made from conventional, easier-to-manufacture materials like cast iron. This localized application of corrosion resistance optimizes durability where needed without unnecessarily increasing manufacturing complexity and cost for the entire 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 achieves high corrosion resistance, secure coupling, and maintains the energizing ring's position despite rotor deformations, ensuring stable anti-lock braking system functionality.
Implementation Method 1
the energizing ring is co-melted in the body of the disc for disc brakes
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A disc assembly (1) for disc brake and energizing ring, or flywheel, comprising a disc for disc brake (2), a braking band (4), a bell (7) for connecting the brake disc (2) to a hub of a vehicle; a connecting portion (8) between said braking band (4) and said bell (7), a connecting portion of an energizing ring (9) connected cantilevered to said bell (7) so as to avoid interfering with said braking band (4) and forming an end surface (10) arranged parallel to the radial direction (R-R), said assembly further comprising an energizing ring (3) comprising an energizing ring body having an energizing side, opposite said disc (2), and coupling side, facing said disc (2), a plurality of projections and/or recesses provided in said energizing side, at least a coupling portion cantilevers from said energizing ring body in an axial direction (A-A) and includes a free end portion, said free end portion of the coupling portion is received in said connecting portion of an energizing ring (9) of the disc (2) passing through said radial end surface (10), said connecting portion of an energizing ring (9) closely surrounding said free end portion of the coupling portion, leaving said energizing ring body free.