Coulomb Friction Damped Brake Rotor Insert
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Solution Overview
Problem
Conventional disc brake systems suffer from unstable friction between brake pads and rotors, leading to resonant vibrations and squeal noise due to low damping capacity in grey cast iron materials, and existing friction damper solutions compromise structural integrity or fail to implement effectively in mass production.
Innovation Solution
A two-part insert with a thin metal core and sheath is embedded in cast components, such as brake rotors, during manufacturing, creating a dry sliding friction contact that increases damping capacity while ensuring structural integrity through rigid bonding and strategic openings for limited infiltration of molten cast iron, minimizing thermal distortion and maintaining effective contact pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If solid inserts are embedded in brake rotors to generate friction damping, then damping capacity is improved, but structural integrity is compromised
Solution Approach 1:
The insert is divided into two distinct parts: a core portion and a sheath portion. The core portion contacts the brake pad to generate friction damping, while the sheath portion is embedded in the rotor to maintain structural integrity. This segmentation allows each part to fulfill its specific function without compromising the other.
Solution Approach 2:
The core portion is nested within the sheath portion, creating a layered structure where the core generates friction damping and the sheath provides structural support. This nested configuration allows the friction interface to be contained within the structurally sound sheath, resolving the contradiction between damping and integrity.
2Ease of operation
If insert surfaces are pre-treated to avoid complete bonding with rotor surfaces, then sliding ability is improved, but bonding strength deteriorates
Solution Approach 1:
Different surface treatments are applied to different parts of the insert. The core portion has a surface treatment that facilitates sliding and friction damping, while the sheath portion has a surface treatment that ensures strong bonding with the rotor. This local differentiation allows each surface to optimize its specific function.
Solution Approach 2:
The insert surface is segmented into two functional zones: the core surface optimized for sliding contact with the brake pad, and the sheath surface optimized for bonding with the rotor material. This segmentation resolves the contradiction by allowing opposite surface properties in different locations.
3Loss of energy
If a two-part insert with core and sheath is used, then damping capacity is improved, but device complexity increases
Solution Approach 1:
The two-part insert (core and sheath) is manufactured as a single integrated component in one casting operation, rather than assembling two separate parts. This merging approach maintains the functional benefits of the two-part structure while eliminating assembly complexity and reducing manufacturing steps.
Solution Approach 2:
The insert structure is designed to be self-contained and self-configuring within the rotor. The core and sheath portions automatically assume their functional roles during operation without requiring external adjustment or complex installation procedures, simplifying the overall system.
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 disc brake rotor squeal noise by enhancing damping capacity without compromising structural integrity, applicable to both rotary and non-rotary components like suspension parts and engine blocks, effectively addressing vibration and noise issues across various temperature conditions.
Implementation Method 1
A dry sliding friction contact is developed at the interface of the core of metal and the encompassing sheath when the component is subject to vibration
Implementation Method 2
coulomb friction damped components
Data Source
AI summary
A friction damping cast component and method of production are disclosed. The components may be rotary, such as a cast brake rotor, or may be non-rotary, such as a cast suspension part or a cast engine block. Regardless of the type of component, a two-part vibration-damping insert having a thin metal core and a thin metal sheath is provided. The sheath fully encompasses the core in such a way that a dry sliding friction contact develops at their interfaces. The outer surface of the sheath with the metal core inside is rigidly bonded to the cast material that surrounds it during the casting process. The sheath surfaces may have a number of openings that allow a limited infiltration of molten cast iron material just inside the immediate vicinity of the sheath openings for spot rigid bonding between the surrounding cast material and the insert surfaces during casting.