Elastic Interlayer Brake Disk for Drag Torque Reduction
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Solution Overview
Problem
Existing brake disk systems experience drag torque issues due to unreliable positioning of brake pads, leading to increased fuel consumption, wear, and noise, which current solutions attempt to address with additional components like retraction springs that are expensive, heavy, and error-prone.
Innovation Solution
A brake disk design featuring a first and second friction ring with an interlayer providing axial elasticity, compressing during brake application and restoring to an outward force that pushes the brake pads away from the disk surface, mimicking the function of a spring without additional components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If retraction springs are added to reduce drag torque, then brake pad positioning reliability improves, but device complexity, weight, and cost increase
Solution Approach 1:
The patent extracts and eliminates the retraction spring component from the brake system. Instead of adding a separate spring mechanism, the restoring force is integrated directly into the brake pad assembly through an elastic element (such as a rubber or polymer material) that is molded into the brake pad structure. This extraction removes the need for additional components while maintaining the drag torque reduction function.
Solution Approach 2:
The patent merges the retraction function with the brake pad structure itself. The elastic element is combined with the friction material and housing to create an integrated assembly where the restoring force is generated as part of the brake pad's inherent structure rather than as a separate mechanism. This merging simplifies the overall device by combining multiple functions into a single component.
2Reliability
If retraction springs are added to reduce drag torque, then brake pad positioning reliability improves, but weight increases
Solution Approach 1:
The patent removes the heavy metal spring component and replaces it with a lightweight elastic material such as rubber or polymer. This extraction of the traditional spring mechanism and substitution with a lighter material directly reduces the weight of the moving brake assembly while maintaining the necessary restoring force for brake pad retraction.
Solution Approach 2:
The patent changes the material parameters from dense metal (spring) to lighter elastomeric materials (rubber or polymer). This parameter change in material density and elasticity allows the same functional requirement (restoring force) to be achieved with significantly reduced weight, as the elastic materials provide sufficient restoring force through their viscoelastic properties rather than through metal spring mechanics.
3Reliability
If retraction springs are added to reduce drag torque, then brake pad positioning reliability improves, but cost increases
Solution Approach 1:
The patent extracts the separate spring component and replaces it with an elastic element that can be molded directly into the brake pad assembly. This extraction eliminates the need for separate spring manufacturing, procurement, and assembly steps, thereby reducing overall manufacturing cost while maintaining the reliability benefit of improved brake pad positioning.
Solution Approach 2:
The patent combines the elastic restoring element with the brake pad housing and friction material into a single integrated component. This merging allows the entire assembly to be manufactured as one piece through molding processes, eliminating multiple assembly steps and reducing labor costs. The integrated design simplifies the manufacturing workflow and reduces the bill of materials compared to assembling separate spring and brake pad components.
4Force
If brake pads are pressed against brake disk, then braking force is generated, but drag torque increases due to unreliable pad positioning
Solution Approach 1:
The patent implements a feedback mechanism through the elastic element that continuously monitors and adjusts brake pad position. When the brake pads are pressed against the disk, the elastic element compresses and stores energy; when the braking force is released, this stored energy provides a restoring force that actively pushes the brake pads back to their correct positioned state. This feedback loop ensures reliable positioning by using the system's own mechanical response to correct positioning deviations, thereby reducing drag torque caused by improper pad positioning.
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
This design effectively reduces drag torque by ensuring consistent brake pad positioning, thereby lowering fuel consumption, wear, and noise, while eliminating the need for costly and heavy retraction springs.
Implementation Method 1
The interlayer has a shape elasticity and is configured to be compressed in an axial direction during application of brake pressure by way of the brake pads
Data Source
AI summary
The invention relates to a brake disk for a disk brake system, comprising a first friction ring for engagement with a first brake pad, a second friction ring for engagement with a second brake pad opposite to the first brake pad, and an interlayer interposed between the first friction ring and the second friction ring, the interlayer having a shape elasticity and being configured to be compressed in an axial direction during application of brake pressure by way of the brake pads. The invention also relates to a disk brake system and use of a disk brake system.