Solid Brake Disc Segmented Hat and Friction Parts
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Solution Overview
Problem
Conventional solid-type brake discs have a dimensional limitation due to the integrated configuration of the hat and friction parts, which restricts their ability to achieve a thinner and lighter design, and they are not optimized for effective stress distribution and thermal management.
Innovation Solution
A solid-type brake disc design where the hat and friction parts are configured separately with a strong coupling structure using protrusions and recessed portions, allowing for a thinner and lighter configuration, improved stress distribution, and enhanced thermal management through the use of different materials and a specific geometric arrangement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the hat part and friction part are integrated to form a single body, then the structural simplicity is maintained, but the dimensional flexibility and weight reduction are limited
Solution Approach 1:
The brake disc is divided into two separate components: a hat part and a friction part. These parts are connected through protrusions extending from the hat part that fit into recesses in the friction part, creating a segmented yet integrated structure that reduces weight while maintaining structural integrity
2Ease of manufacture
If the hat part and friction part are integrated to form a single body, then the manufacturing process is simplified, but the thermal management and stress distribution are not optimized
Solution Approach 1:
By separating the hat part and friction part into distinct components with different material properties, the design enables optimized thermal management. The friction part can be made from materials with superior heat dissipation characteristics, while the hat part can be optimized for mechanical strength and torque transmission
Solution Approach 2:
Different regions of the brake disc are made from different materials with properties optimized for their specific functions. The friction part uses materials tailored for heat dissipation and friction characteristics, while the hat part uses materials optimized for structural integrity and torque load bearing
3Stability of the object's composition
If the hat part and friction part are integrated to form a single body, then the structural integrity is maintained, but the coupling strength between components is insufficient
Solution Approach 1:
The connection between hat part and friction part is achieved through multiple protrusions that extend into recesses, creating a segmented connection structure. This segmentation allows for distributed stress transfer and strong coupling while maintaining the ability to separate components if needed
Solution Approach 2:
The protrusions and recesses are designed to merge the hat part and friction part into a unified load-bearing structure. The geometric interlocking creates a combined structure that distributes stresses evenly across the connection interface, achieving coupling strength comparable to or exceeding fully integrated designs
Data Source
AI summary
Disclosed is a solid-type brake disc including a hat part, which includes a circular main body mounted on a rotation shaft of a wheel, and a plurality of protrusions protruding in a circumferential direction from an outside surface of the main body, and a friction part, which includes a ring body having a through-hole formed in the center thereof for receiving the hat part in the through-hole, and recessed portions protruding from the periphery of the through-hole toward the respective protrusions, the recessed portions being connected to the respective protrusions to enclose the protrusions.