Segmented Sintered Clutch Disc for Organic Carrier Compatibility

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Solution Overview

Problem

Existing friction discs designed for organic friction linings cannot accommodate sintered friction linings due to geometric incompatibility, limiting the use of high-wear-resistant inorganic materials in organic-based structures.

Innovation Solution

The integration of sintered friction lining segments with angle coverage between 25° and 55° and adaptable fastening lugs or lining spring elements allows for mounting on organic friction lining carriers, enabling the replacement of organic linings with sintered ones in clutches or brakes without major conversions, and optimizing the mass distribution for extended lifespan.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If sintered friction lining is used, then wear resistance and temperature resistance are improved, but geometric compatibility with organic friction lining carriers is lost

Engineering Contradiction:

Improvewear resistanceVSAvoidgeometric compatibility

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The sintered friction lining is divided into multiple segments that can be individually mounted on the carrier element. Each segment has a specific angle coverage (25°-55°) and includes fastening points for connection, allowing the rigid sintered material to be adapted to the carrier geometry through modular assembly rather than requiring a single continuous piece

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The friction lining segments are mounted within the existing carrier element structure designed for organic linings. The segments nest into the carrier's geometry, utilizing the existing fastening lug or spring element arrangement while accommodating the different material form factor of sintered lining through precise angular positioning

Inventive Principle:

Principle #7Nested doll (Nesting)

2Adaptability or versatility

If friction lining segments with angle coverage between 25° and 55° are used, then adaptability to organic friction lining carriers is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvemounting compatibilityVSAvoidmanufacturing complexity

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The angle coverage parameter is specifically optimized to range between 25° and 55° to balance two competing requirements: sufficient angular coverage for proper friction surface area while leaving adequate space for fastening lugs or spring elements. This parameter optimization enables standard mounting procedures without requiring complex custom fabrication for each segment

Inventive Principle:

Principle #35Parameter changes

3Weight of moving object

If fastening lugs or lining spring elements are reduced in size, then mass of carrier element is reduced, but fastening strength may be compromised

Engineering Contradiction:

Improvecarrier element massVSAvoidfastening strength

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The fastening system utilizes a composite approach where the fastening lugs or spring elements (metallic components) connect the sintered friction lining segments to the carrier element. The spring elements provide both mechanical strength for secure attachment and elastic compliance to accommodate thermal expansion and operational stresses, maintaining fastening strength while minimizing mass

Inventive Principle:

Principle #40Composite materials

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 solution enables the use of sintered friction linings in organic-based structures, enhancing wear resistance and temperature consistency while allowing for easier replacement and adaptation to different fastening situations, thus extending the lifespan and improving performance in clutches or brakes.

Implementation Method 1

the friction lining segments each connect two fastening lugs or lining spring elements to one another

Methodology Applied

Scientific EffectMechanical Fastening: Mechanical Fastener

Implementation Method 2

the fastening of the friction linings additionally has a springy effect

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS11371574B2Friction disc or clutch disc

Publication Date: 2022.06.28 MIBA FRICTEC

AI summary

A friction device has a carrier element and friction lining segments arranged thereon. The friction lining segments each include a sintered friction lining, which is arranged on a friction lining carrier, the friction lining carrier is connected to the carrier element, and preferably the carrier element includes multiple fastening lugs and/or lining spring elements for the friction lining segments. In the design of the carrier element with the fastening lugs and/or lining spring elements, the friction lining segments each connect two fastening lugs or two lining spring elements to one another and/or the friction lining segments have an angle coverage between 25° and 55°.