Floating Brake Disc Assembly With Debris-Resistant Band Connection
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Solution Overview
Problem
Current disc brake solutions face issues with uneven wear and imbalance due to manufacturing and assembly tolerances, leading to premature damage and increased maintenance needs, particularly in high-performance vehicles, where high friction generates asymmetric clamping stresses and thermal deformations, and the accumulation of dust and debris affects axial mobility.
Innovation Solution
A brake disc assembly with a separate brake band and bell, connected by a single-piece connecting device that allows axial float without biasing, using a male element and elastic element to prevent dust and debris accumulation and ensure axial mobility, while allowing the bell to be made of a softer, lighter material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the brake band is made separate from the bell to allow different materials (friction-resistant brake band, lighter bell), then weight is reduced and material optimization is achieved, but the connection between brake band and bell becomes critical and complex
Solution Approach 1:
The brake disc assembly is divided into separate brake band and bell components, each optimized for its specific function. The brake band uses friction-resistant material while the bell uses lighter material, achieving weight reduction through functional segmentation.
Solution Approach 2:
A connecting device acts as an intermediary between the brake band and bell, providing a secure mechanical connection that transfers braking torque while accommodating thermal expansion and manufacturing tolerances. This mediator simplifies the overall connection system.
2Reliability
If axial float is provided to allow brake band to settle halfway between opposite pads, then imbalance of forces and plastic deformation are prevented, but dust and debris accumulation in the connection area increases
Solution Approach 1:
The connecting device serves as a mediator that enables axial float functionality while protecting the connection area from dust and debris. It allows the brake band to move axially to settle halfway between pads, preventing force imbalance and plastic deformation, while simultaneously shielding the connection interface.
Solution Approach 2:
A dust cover or protective shielding (analogous to flexible shell/film concept) is used to protect the connection area between brake band and bell from dust and debris accumulation, while still allowing the necessary axial movement for float functionality.
3Ease of operation
If elastic preload is applied to enable axial float, then the brake band can slide to settle position, but the connecting components experience increased wear and damage
Solution Approach 1:
The connecting device is designed as a specialized intermediary that accommodates axial float movements without experiencing excessive wear. It provides a controlled interface that allows the brake band to slide to its settlement position while protecting the connection components from damage.
Solution Approach 2:
The connecting device incorporates features that cushion and protect against the effects of axial float movements before damage can occur. This preemptive design approach extends the service life of connecting components by preventing wear and damage from the axial sliding action.
4Manufacturing precision
If manufacturing and assembly tolerances are accommodated, then asymmetric clamping stresses are reduced, but additional clearance and float mechanisms are required
Solution Approach 1:
The connecting device acts as a tolerance-absorbing intermediary between the brake band and bell. It provides built-in clearance and float capabilities that accommodate manufacturing and assembly tolerances, reducing asymmetric clamping stresses without requiring complex additional mechanisms.
Solution Approach 2:
The connecting device incorporates adjustable parameters such as clearance distances and float ranges that can be optimized to accommodate manufacturing tolerances. By carefully selecting these parameters, the system absorbs tolerance variations and reduces asymmetric stresses.
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 enables reduced wear, improved axial float, and minimized debris accumulation, enhancing the brake disc's performance and longevity without increasing weight or component count, suitable for high-performance vehicles.
Implementation Method 1
at least one elastic element, adapted to elastically bias said brake band away from said bell
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
A brake disc assembly (1) comprising: a brake band (2), a bell (3), adapted to be operatively connected to a vehicle wheel associable with the brake disc assembly (1), and at least one connecting device (4), which forms a connection between said brake band (2) and said bell (3); said connecting device (4) and said bell (3) cooperate by delimiting at least one axial band seat (5) where the brake band (2) may slide in an axial direction (X-X) of a predetermined axial stroke; said bell (3) comprises at least a first end-of-stroke surface (6) which forms a first abutment surface in the axial direction (X-X) for said brake band (2); said connecting device (4) comprises a second end-of-stroke surface (7), opposite to said first end-of-stroke surface (6), which forms a second opposite abutment surface in the axial direction (X-X) for said brake band (2); said connecting device (4) comprises at least one male element (8), which is accommodated in at least one male element bell seat (14) obtained in said bell (3); said male element (8) comprises at least one bell abutment surface (9); said bell (3) comprises at least one male element abutment surface (10); said bell abutment surface (9) of the male element (8) forming an abutment surface in the axial direction (X-X) for said male element abutment surface (10) of the bell (3) so as to avoid said connecting device (4) and said bell (3) from tightening said brake band (2) therebetween.