Wear Liner With Integrated Torque Buttons for Brake Disk Coupling
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Solution Overview
Problem
Current aircraft braking systems face issues with torque transfer and material waste due to the attachment of wear liners via flanges, which can lead to increased costs and limited wearable surface area.
Innovation Solution
The integration of torque buttons on wear liners allows for secure coupling to the friction disk core via fasteners, enabling efficient torque transfer and maximizing the usable material surface, while also allowing for interchangeability between rotor and stator assemblies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If wear liners are attached to the friction disk core via a flange, then the liner can be securely attached, but torque transfer problems occur particularly when the liner is in a worn state
Solution Approach 1:
The wear liner is segmented to include integrated torque buttons that protrude from the non-wear surface. These torque buttons are positioned to engage with corresponding features on the friction disk core, creating distributed torque transfer paths that remain effective even as the wear surface degrades. This segmentation allows the attachment function to be separated from the wear function, solving the contradiction between initial attachment strength and sustained torque transfer reliability.
Solution Approach 2:
The torque buttons extend in the axial dimension from the non-wear surface, creating a three-dimensional engagement mechanism rather than relying solely on the two-dimensional flange interface. This dimensional addition provides torque transfer pathways that are independent of the wear surface condition, maintaining reliability as the liner wears.
2Ease of manufacture
If the liner is attached via a flange, then attachment is achieved, but material costs increase and material waste occurs as a large area is dedicated to the flange with limited wearable surface
Solution Approach 1:
The attachment function and the structural body of the wear liner are merged into a single integrated component. The torque buttons are formed as integral features of the wear liner itself, eliminating the need for a separate flange structure. This merging reduces material consumption by removing redundant attachment structures while maintaining secure attachment capability through the distributed torque button engagement.
Solution Approach 2:
The traditional flange structure is extracted and replaced with integrated torque buttons that are formed directly on the wear liner. This extraction removes the non-functional material dedicated to flange attachment, maximizing the proportion of material that contributes to the wearable friction surface and reducing overall material waste.
3Ease of manufacture
If wear liners are attached via flange, then attachment is achieved, but the amount of wearable surface is limited
Solution Approach 1:
The attachment features (torque buttons) are merged directly into the wear liner body, allowing the wearable surface to extend continuously to the outer boundaries of the liner. Without a separate flange structure occupying peripheral area, the maximum possible wearable surface area is achieved while maintaining secure attachment through the integrated torque buttons.
4Reliability
If wear liners are designed with integrated torque buttons, then torque transfer efficiency is enhanced and material waste is reduced, but manufacturing complexity increases
Solution Approach 1:
The torque buttons are merged as integral features of the wear liner manufacturing process rather than being added as separate components. This integration allows the torque transfer enhancement to be achieved through the basic liner forming operation, minimizing additional manufacturing complexity while maximizing torque transfer efficiency and reducing the need for separate attachment components.
Data Source
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AI summary
A friction disk may comprise a friction disk core (49) and a wear liner (50) coupled to the friction disk core (49). A depression (120) may be formed in a surface of the friction disk core (49). The wear liner (50) may comprise a protrusion (160) extending from a non-wear surface of the wear liner (50). The protrusion (160) may be positioned within the depression of the friction disk core.