Floating Disc Brake Rotor Attachment Using an Expander Ring
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Solution Overview
Problem
Integrated one-piece rotor and hat assemblies face thermal distortion and stress issues due to constrained thermal expansion, leading to vibration, cracking, and reduced performance, while conventional fastener-based designs suffer from bending and fatigue stresses, causing premature wear and maintenance challenges.
Innovation Solution
A floating disc brake assembly using an expander ring with a radial wave, fitted within grooves of both the rotor and hat, applies radial pressure to secure the rotor to the hat, minimizing bending stresses and ensuring uniform torque transfer, and is made of spring steel for enhanced durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If an integrated one-piece rotor and hat assembly is used, then the structure is simplified and no fasteners are required, but thermal distortion and stress lead to vibration, cracking, and reduced performance
Solution Approach 1:
The brake assembly is divided into separate rotor and hat components that can float relative to each other, allowing thermal expansion without stress while maintaining structural simplicity. The rotor is detached from the hat, enabling independent thermal movement.
Solution Approach 2:
The rotor is designed to float dynamically on the hat rather than being rigidly fixed, allowing it to move axially and radially in response to thermal expansion. This dynamic adjustment prevents thermal stress and distortion while maintaining braking performance.
2Strength
If conventional fastener-based designs are used, then the rotor is securely attached to the hat, but bending and fatigue stresses cause premature wear and maintenance challenges
Solution Approach 1:
Fasteners are completely removed from the design. The rotor attaches to the hat through floating contact surfaces without bolts, nuts, or other fastening elements, eliminating the source of bending and fatigue stresses that lead to premature failure.
Solution Approach 2:
The attachment mechanism transitions from rigid mechanical fastening to elastic floating contact, changing the physical state of the connection from fixed to compliant. This allows the assembly to accommodate thermal expansion while maintaining secure attachment.
3Stability of the object's composition
If the rotor is constrained at the hat, then the assembly structure is stable, but thermal expansion is limited causing thermal coning and high thermal stress
Solution Approach 1:
The rotor is designed to float dynamically on the hat rather than being rigidly fixed, allowing it to move axially and radially in response to thermal expansion. This dynamic adjustment prevents thermal stress and distortion while maintaining braking performance.
Solution Approach 2:
The floating design explicitly accommodates thermal expansion by allowing the rotor to move independently from the hat. The rotor can expand radially and axially without constraint, preventing thermal coning and high thermal stress while maintaining assembly stability through gravitational and contact forces.
4Temperature
If a floating rotor design is used, then thermal expansion is accommodated, but lateral separation and twisting can occur reducing reliability
Solution Approach 1:
The attachment geometry is designed with features that constrain movement in lateral and rotational dimensions while permitting thermal expansion in the axial dimension. This dimensional differentiation allows thermal movement without compromising attachment reliability.
Solution Approach 2:
The attachment mechanism transitions from rigid mechanical fastening to elastic floating contact, changing the physical state of the connection from fixed to compliant. This allows the assembly to accommodate thermal expansion while maintaining secure attachment.
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 effectively reduces thermal stress and fatigue, increasing the life and reliability of the brake assembly by preventing lateral separation and twisting, thus minimizing maintenance costs and improving braking performance.
Implementation Method 1
The expander ring is made of spring steel for enhanced durability
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
A floating disc brake assembly, and method of assembly, comprising a disc brake rotor (100) comprising an outer friction ring, an inner circumferential flange having a plurality of rotor tabs (106) spaced about the flange and a circumferential groove about the inner circumferential flange, a hat (130) comprising a cylindrical axial body, an outer circumference, a rotor mounting flange (134) extending radially about the outer circumference and having a plurality of rotor mounting tabs (136) spaced about the rotor mounting flange and forming slots (137) interspersed therebetween structured and arranged for receiving the rotor tabs, and a circumferential groove about the outer circumference of the axial body, structured and arranged to align with the circumferential groove of the disc brake rotor, and at least one expander ring (120) structured and arranged to fit within the circumferential grooves of both the rotor and the hat.