Modular Brake Rotor Inserts for Wear and Transfer Film Retention
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Solution Overview
Problem
Conventional braking systems experience wear and corrosion of friction surfaces due to abrasive friction, leading to the need for frequent re-machining or replacement of brake rotors, and lack efficient methods for retaining brake pad material for enhanced braking performance.
Innovation Solution
A modular brake rotor assembly with stainless steel friction surface parts featuring multiple levels of surface topography and a wear and corrosion-resistant coating, which are fixably attached to a structural part, enhancing adhesive friction and reducing wear through a transfer film layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If conventional brake rotors are used with friction surfaces, then braking function is provided, but wear and corrosion occur leading to frequent re-machining or replacement
Solution Approach 1:
The brake rotor is divided into a structural part and separate friction surface parts that can be independently replaced. The friction surface parts are detachably attached to the structural part, allowing only the worn friction surfaces to be replaced while retaining the structural part, thus reducing material loss and extending overall service life.
Solution Approach 2:
The friction surface parts are made from materials with optimized parameters for wear and corrosion resistance, such as stainless steel or ceramic coatings. The surface topology is also modified with specific roughness parameters to enhance material retention and braking performance, directly addressing the wear and corrosion problem.
2Reliability
If friction surfaces are made more durable, then wear resistance improves, but manufacturing complexity increases
Solution Approach 1:
By segmenting the brake rotor into modular components (structural part and friction surface parts), the complexity is localized to the attachment mechanism while allowing each component to be optimized independently for reliability. This modular approach actually simplifies manufacturing and maintenance compared to monolithic designs.
Solution Approach 2:
The friction surface parts utilize composite material structures, such as stainless steel substrates with ceramic coatings or multi-layer composite materials, achieving superior wear and corrosion resistance. These composite structures are manufactured as separate components and attached to the structural part, managing complexity through material selection rather than structural complexity.
3Power
If brake pad material is retained on the rotor surface, then adhesive friction enhances braking efficiency, but material accumulation may occur
Solution Approach 1:
The friction surface parts feature localized quality variations through controlled surface topology with specific roughness parameters. This creates optimal local conditions for brake pad material retention and transfer film formation, enhancing adhesive friction and braking efficiency while preventing excessive material accumulation through the designed surface characteristics.
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 modular design with surface topography and coatings significantly extends the lifespan of brake rotor assemblies by reducing wear, improving braking efficiency, and providing a progressive, linear braking feel while minimizing environmental impact from debris.
Implementation Method 1
The contact surface of the friction surface part includes a wear and corrosion resistant coating
Implementation Method 2
The contact surface of the friction surface part includes a wear and corrosion resistant coating
Implementation Method 3
The transferred film or layer of brake pad material can enhance braking by participating in adhesive friction with a brake pad
Implementation Method 4
The one or more levels of surface topography can include a first level that includes island formations separated by channels. The one or more levels of surface topography can further include a second level comprising raised peaks with spaced valleys between the peaks.
Implementation Method 5
a brake pad that includes a friction material, and an apparatus for urging the friction material of the brake pad against the annular braking surface to slow rotation of the brake rotor assembly
Data Source
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AI summary
A brake rotor assembly (200) can include a structural part (202) having a receiving surface (206) and at least one friction surface part (204) having a contact surface. The friction surface part can be fixably attached to the receiving surface of the structural part (202) such that the contact surface faces away from the receiving surface of the structural surface to form at least part of an annular braking surface arranged concentrically around an axis of rotation of the structural part.