Floating Rotor Disc Brake Retention Ring Fastener
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Solution Overview
Problem
Existing floating disc brake assemblies face issues with bending and fatigue stresses due to non-uniform torque transfer and thermal expansion, leading to potential cracking and increased maintenance costs, as well as damage to the rotor and hub components.
Innovation Solution
A floating disc brake assembly design featuring a disc brake rotor with radial tabs and a hub having uniformly spaced rotor mounting tabs and slots, secured by a retention ring that minimizes moment arm and bending stresses, allowing for in-plane torque transfer and accommodating thermal expansion without apertures or through holes, using a retention ring that is radially yieldable for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional fastener assemblies (bolts/studs with nuts) are used to connect rotor to hub, then the rotor can be securely attached, but bending stresses and fatigue are induced due to moment arm created by axial displacement, leading to cracking and breaking
Solution Approach 1:
The patent removes the conventional fastener assembly (bolts, studs, nuts) and replaces it with a retention ring that engages with slots in the hub and tabs on the rotor. This extraction eliminates the moment arm problem caused by axial displacement of fasteners, thereby preventing bending stresses and fatigue that lead to cracking and breaking while maintaining secure attachment.
Solution Approach 2:
The retention ring acts as an intermediary component between the rotor and hub. It features slots that receive hub protrusions and engages with rotor tabs, creating a connection mechanism that minimizes moment arm and bending stresses. The retention ring distributes forces uniformly across multiple engagement points, preventing localized stress concentrations that cause cracking.
2Stability of the object's composition
If the rotor is rigidly connected to the hub, then structural stability is improved, but thermal expansion is constrained causing thermal coning, thermal gradient, and thermal stress leading to thermal cracking
Solution Approach 1:
The patent creates a dynamic connection between the rotor and hub using the retention ring with slots and protrusions. This allows the rotor to float and move slightly relative to the hub, accommodating thermal expansion in the radial direction while maintaining structural stability. The slots provide clearance that enables thermal growth without constraint, preventing thermal coning and thermal stress.
Solution Approach 2:
The retention ring design changes the connection parameters from rigid fixed positions to floating positions with controlled clearance. The slots in the retention ring and corresponding protrusions on the hub create a connection that maintains structural integrity while allowing thermal expansion movements, thereby preventing thermal cracking.
3Temperature
If a floating rotor design with clearance is used, then thermal expansion is accommodated, but non-uniform torque transfer through perforated flange causes high stresses at individual apertures, leading to cracking or breakage
Solution Approach 1:
The patent segments the connection interface into multiple discrete slots and corresponding protrusions around the circumference. This segmentation distributes the torque transfer across multiple engagement points rather than concentrating it at individual apertures. The slots in the retention ring and protrusions on the hub create multiple load paths, reducing stress at any single location and preventing cracking or breakage.
4Device complexity
If integrated one-piece rotor and hub assembly is used, then no fasteners are required eliminating wear and fatigue problems, but the assembly is constrained at the hub causing thermal distortion and requiring complete replacement when damaged
Solution Approach 1:
The patent segments the brake assembly into separable rotor and hub components connected by the retention ring. This allows the rotor to be detached and replaced independently from the hub, eliminating the need for complete assembly replacement when the rotor is damaged. The slot-and-retention ring connection provides a simple mechanical interface that enables easy separation and reassembly.
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 enhances the life and reliability of the brake assembly by reducing bending and fatigue stresses, ensuring uniform torque distribution, and allowing the rotor to float relative to the hub, thereby minimizing thermal distortion and maintenance costs.
Implementation Method 1
allowing for in-plane torque transfer and accommodating thermal expansion without apertures or through holes
Data Source
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AI summary
A floating disc brake assembly having a disc brake rotor (120) secured to a hub (110) with a retention ring (130) structured and arranged to fit within retention ring flanges (118) of a plurality of rotor mounting tabs (112) extending from the hub. A method of uniformly transferring braking forces from a rotor of a brake assembly about a hub of the brake assembly and a kit of parts are also provided.