Rivet-less Rotor Clip Retention for Carbon Brake Disks
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Solution Overview
Problem
Existing brake disk systems for aircraft, particularly those using carbon brake disks, face issues with damage during rivet removal and clip installation, leading to costly replacements and potential damage from floating clips.
Innovation Solution
A brake disk assembly with a rotor disk featuring a circumferentially positioned undercut engagement portion and a rotor clip with a tab engagement portion and undercut coupling portion, including bumps, which allows for secure engagement and retention without damaging the carbon brake disk, enabling easy installation and removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rivets are used to secure rotor clips on carbon brake disks, then the rotor clips are securely retained, but the carbon brake disk is damaged during rivet removal
Solution Approach 1:
The patent extracts the harmful rivet fastening method and replaces it with a rivet-less retention system. The rotor clip is retained through an undercut engagement portion that mechanically interlocks with the rotor disk without requiring rivets, thereby eliminating the damage caused by rivet removal while maintaining secure retention
Solution Approach 2:
The patent introduces an undercut engagement portion as an intermediary mechanical feature between the rotor clip and rotor disk. This undercut portion acts as a mediator that provides secure retention through geometric interlocking rather than through rivets, preventing direct contact and damage between fastening elements and the carbon disk
2Adaptability or versatility
If floating clips are used in rotor assemblies, then the clips can move freely, but the clips may cause damage to the carbon brake disk
Solution Approach 1:
The patent removes the harmful floating clip design and replaces it with a retained rotor clip system. The rotor clip is securely positioned through the undercut engagement portion, preventing uncontrolled movement and potential damage to the carbon brake disk while maintaining necessary positioning freedom
3Reliability
If rotor clips are securely retained on carbon brake disks, then the retention is reliable, but the installation and removal processes cause damage
Solution Approach 1:
The undercut engagement portion is pre-formed on the rotor disk during manufacturing, creating a ready-to-use retention feature. This preliminary action allows the rotor clip to be easily installed and removed without damage, as the retention mechanism is already in place and does not require additional fastening operations
Data Source
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AI summary
A rotor disk assembly includes a rotor disk (102). The rotor disk (102) includes a first rotor lug (150), a second rotor lug (151) circumferentially spaced from the first rotor lug (150) and defining a slot (257) therebetween. The slot is located on a radially outward portion of the rotor disk and the slot (257) has an undercut engagement portion (270) defined by the first rotor lug (150) and the second rotor lug (151). The undercut engagement portion (270) is positioned circumferentially on the rotor disk to engage a rotor clip (114).