Split Friction Disk Brake Assembly for Vibration Damping
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Solution Overview
Problem
Aircraft brake assemblies face issues with torque and vibrations during use, and the manufacturing of thick friction disks is challenging due to their limited thickness as unitary pieces.
Innovation Solution
A disk brake system comprising split friction disks with a damping feature of lower density between the disk halves, allowing for thicker end and pressure plates to shift composite material, reducing stator and rotor disk thicknesses, and using carbon composite materials to minimize vibrations and noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thick friction disks are manufactured as unitary pieces, then structural integrity is improved, but manufacturing difficulty increases significantly
Solution Approach 1:
The friction disks are divided into multiple thinner disk halves (rotor disk halves and stator disk halves) that can be manufactured separately as unitary pieces with improved ease of manufacture, then assembled together with damping features to form the complete brake assembly that maintains structural integrity
2Ease of manufacture
If friction disks are made thinner to ease manufacturing, then manufacturing difficulty is reduced, but vibration damping capability worsens
Solution Approach 1:
Damping features (such as damping material or dampers) are introduced as intermediary elements between the rotor disk halves and stator disk halves to provide vibration damping capability, compensating for the reduced thickness of the individual friction disks while maintaining manufacturing ease
Solution Approach 2:
The brake assembly uses composite construction with different materials serving different functions: friction materials for braking, and damping materials with different density and damping characteristics for vibration control, creating a composite structure that achieves both manufacturing ease and vibration damping
3Object-affected harmful factors
If carbon composite materials are used, then vibration and noise are reduced, but material selection complexity increases
Solution Approach 1:
The damping features utilize carbon composite materials with specifically controlled density parameters (different from the friction disk materials) and damping characteristics to optimize vibration and noise reduction while maintaining compatibility with the overall brake assembly design
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
The system effectively dampens vibrations and noise while enabling easier manufacturing of thinner friction disks, enhancing the brake's effectiveness and reducing manufacturing difficulties.
Implementation Method 1
a damping feature located axially between a split friction disk first half and a split friction disk second half. The damping feature may have a density that is less than the rotor density and the stator density
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3C
AI summary
A disk brake system comprises a pressure plate (30) coupled axially to a rotor friction disk (42) having a rotor density and a stator friction disk (40) having a stator density located axially between the pressure plate and an end plate (32). The rotor friction disk and the stator friction disk are annular disks, and the rotor friction disk and the stator friction disk are adjacent to one another and disposed coaxially and at least one of the rotor friction disk and the stator friction disk is a split friction disk comprising a split friction disk first half and a split friction disk second half (82). The disk brake system also comprises a damping feature (50), having a dampening feature density, located axially between the split friction disk first half and the split friction disk second half.