Replaceable Brake Disc Plates Without Wear-Surface Fasteners
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Solution Overview
Problem
Existing brake disc designs for heavy-duty vehicles face challenges with wear and maintenance, particularly due to the use of screws or bolts that wear out and complicate the replacement of disc plates, leading to uneven wear and reduced braking efficiency.
Innovation Solution
A brake disc design featuring a central disc body with two disc plates that are releasably secured on either side, connected by a single resilient connecting member that extends through a passage in the central disc body, preventing relative rotation without protruding at the wear surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If screws or bolts are used to fix disc plates to the central disc body, then the disc plates can be securely attached, but the screws or bolts wear out due to brake pad contact and complicate replacement
Solution Approach 1:
The harmful screws or bolts that cause wear and replacement difficulties are completely removed from the system. Instead, a resilient connecting member is used that passes through the central disc body and secures disc plates without contacting the brake pads, thereby extracting the problematic fastening elements from the wear zone.
Solution Approach 2:
A resilient connecting member acts as an intermediary element that transfers the securing function from the worn-out screw/bolt system to a new system. This connecting member passes through the central disc body and engages with the disc plates without being exposed to brake pad contact, mediating between the central disc body and disc plates while avoiding the wear problem.
2Stability of the object's composition
If screws or bolts are used to secure disc plates, then relative rotation can be prevented, but the heads of screws or bolts wear and reduce strength
Solution Approach 1:
The screw or bolt heads that are subject to wear are extracted from the system entirely. The resilient connecting member achieves rotational prevention through its resilient engagement with the central disc body and disc plates, eliminating the exposed head components that would otherwise wear and fail.
Solution Approach 2:
The fastening mechanism changes from a rigid screw/bolt system to a resilient connecting member system. This parameter change in the mechanical properties (from rigid to resilient) allows the connecting member to prevent rotation through elastic deformation rather than through exposed threads and heads that are subject to wear.
3Strength
If multiple screws or bolts are used on each side of the disc plate, then secure attachment is achieved, but the device complexity increases
Solution Approach 1:
The fastening function that previously required multiple screws or bolts on each side of the disc plate is merged into a single resilient connecting member that passes through the central disc body. This combining of multiple fastening elements into one integrated component reduces device complexity while maintaining attachment strength.
Solution Approach 2:
The resilient connecting member serves multiple functions simultaneously: it prevents rotation, secures the disc plates to the central disc body, and does so with a single component rather than multiple fasteners. This multi-functionality reduces the overall complexity of the fastening 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
This design allows for efficient and simple replacement of disc plates without the need for screws or bolts at the wear surface, reducing wear and improving braking efficiency while maintaining structural integrity.
Implementation Method 1
The connecting member may suitably be resilient (compressible and expandable) in the radial direction such that it presses against the passage walls and is firmly kept in place
Data Source
AI summary
A brake disc configured to be connected to a vehicle axle and to be squeezed between brake pads, comprising a central disc body (30) having a first and a second side (32, 34), wherein the second side faces in the opposite direction compared to the first side; a first and a second disc plate (36, 38), each disc plate having a wear surface for producing friction when a brake pad is pressed against the wear surface. The disc plates are releasably secured to said first side and second sides, respectively, so as to enable the first and second disc plates to be replaced by other disc plates. A connecting member (64) prevents rotation of the disc plates relative to the central disc body, the connecting member extending from the first disc plate, through a passage (58) in the central disc body, to the second disc plate. Also presented is a vehicle comprising such a brake disc.