Segmented Friction Disc Geometry for Cooling and Weight Reduction
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Solution Overview
Problem
Friction discs in disc friction systems face challenges in weight reduction and stability while maintaining effective cooling and torque transmission, as existing designs often rely on circular shapes that limit the use of larger carrier rings and hinder coolant flow.
Innovation Solution
The friction disc features a geometry deviating from the circular ring shape, with annular friction linings and strategically placed openings along the axial direction, allowing for improved coolant distribution and reduced drag torques, and optionally featuring scatter-sintered linings and beveled edges for enhanced performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a circular ring shape is used for the friction lining, then the structural simplicity and manufacturing ease are improved, but the weight reduction and coolant flow efficiency deteriorate
Solution Approach 1:
The friction lining is divided into multiple segments rather than forming a complete circular ring. This segmentation removes material to reduce weight while maintaining the essential friction surface area and structural integrity through the carrier ring.
Solution Approach 2:
The friction lining adopts an asymmetric geometry that deviates from the traditional circular ring shape. This asymmetric design optimizes the distribution of material to achieve weight reduction while preserving functional performance.
2Ease of manufacture
If a circular ring shape is used for the friction lining, then the manufacturing simplicity is improved, but the coolant distribution and flow efficiency deteriorate
Solution Approach 1:
The segmented design of the friction lining creates gaps that serve as channels for coolant flow. This segmentation allows coolant to penetrate and circulate more effectively through the friction disc, improving cooling efficiency.
Solution Approach 2:
The asymmetric geometry of the friction lining is designed to optimize coolant flow paths. The non-circular shape creates favorable hydrodynamic conditions for coolant distribution across the friction surfaces.
3Stability of the object's composition
If a larger carrier ring is used to increase stability and momentum transmission, then the stability and torque transmission are improved, but the weight increases
Solution Approach 1:
By segmenting the friction lining rather than using a complete ring, the design allows for a larger carrier ring diameter that provides enhanced stability and momentum transmission capability without the full weight penalty of a complete circular friction lining.
Solution Approach 2:
The asymmetric friction lining geometry enables the carrier ring to be optimized for stability and torque transmission while removing unnecessary material from the friction lining itself, achieving a balance between structural performance and weight.
4Temperature
If openings are formed in the friction lining starting from the inner or outer circumference, then the coolant flow out of the friction disc surfaces is improved, but the structural integrity may deteriorate
Solution Approach 1:
The asymmetric positioning and configuration of openings that start from the inner or outer circumference are designed to optimize coolant egress while maintaining structural integrity. The non-uniform distribution of openings prevents weak points that would compromise strength.
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 achieves weight reduction with increased stability and improved coolant flow, enabling efficient torque transmission and adaptability to tribological properties, while maintaining or enhancing performance compared to traditional designs.
Implementation Method 1
a first annular friction lining is arranged on the first surface
Implementation Method 2
at least one opening is formed in the first friction lining in the axial direction, which extends in the axial direction also through the carrier ring, wherein the opening is formed to start at an inner circumference or at an outer circumference of the carrier ring
Data Source
AI summary
A friction disc has a flat carrier ring which includes a first surface and a second surface, wherein a first annular friction lining is arranged on the first surface, the first annular friction lining including a geometry that deviates from the circular ring shape, wherein the carrier ring also includes the geometry of the first friction lining, each as viewed in the axial direction, and/or the first annular friction lining including at least one opening in the axial direction, which extends in the axial direction also through the carrier ring, wherein the opening is formed to start at the inner circumference or at the outer circumference of the carrier ring.