Carbon-carbon composite disc brake assembly

Patent metadata

Field	Value
Publication number	US-2018252284-A1
Application number	US-201715447960-A
Country	US
Kind code	A1
Filing date	Mar 2, 2017
Priority date	Mar 2, 2017
Publication date	Sep 6, 2018
Grant date	—

Abstract

In some examples, a disc brake assembly and methods of forming and assembling said brake disc assembly. The brake disc assembly including a core structure and a plurality of wear pads. The core structure having a first major surface comprising at least one curved ridge or curved channel that extends in a radial direction along the first major surface between an inner and outer diameter of the core structure. Each wear pad defining a friction surface and a mounting surface such that the mounting surfaces of the plurality of wear pads are positioned adjacent to, and in contact with, the first major surface of the core structure, where at least one of the mounting surfaces of the plurality of wear pads includes a corresponding curved ridge or curved channel configured to interlink with the at least one curved ridge or curved channel of the core structure.

First claim

1 . A disc brake assembly comprising:
a core structure defining an inner and outer diameter, the core structure having a first major surface comprising at least one curved ridge or curved channel that curves as the curved ridge or curved channel extends in a radial direction along the first major surface between the inner and outer diameter of the core structure; and a plurality of wear pads, each wear pad defining a friction surface and a mounting surface, wherein the mounting surfaces of the plurality of wear pads are positioned adjacent to, and in contact with, the first major surface of the core structure, wherein the mounting surface of at least one wear pad of the plurality of wear pads comprises a corresponding curved ridge or curved channel that curves as the corresponding curved ridge or curved channel extends in the radial direction along the mounting surface, wherein the corresponding curved ridge or curved channel is configured to interlink with the at least one curved ridge or curved channel of the core structure.

2 . The disc brake assembly of claim 1 , wherein the at least one curved ridge or curved channel of the core structure comprises a first plurality of curved ridges or curved channels, wherein for each wear pad, the mounting surface of the wear pad comprises at least one corresponding curved ridge or curved channel that curves as the at least one corresponding curved ridge or curved channel extends in the radial direction along the mounting surface, wherein the at least one corresponding curved ridge or curved channel of each wear pad is configured to interlink with at least one curved ridge or curved channel of the first plurality of curved ridges or curved channels.

3 . The disc brake assembly of claim 1 , wherein the at least one curved ridge or curved channel of the core structure and the corresponding curved ridge or curved channel of the at least one wear pad each define an undulated shape extending in the radial direction.

4 . The disc brake assembly of claim 1 ,
wherein a first wear pad of the plurality of wear pads comprises a retaining tab integral to the first wear pad and protruding from an inner or outer edge of the first wear pad, wherein the retaining tab does not form part of the friction surface, and wherein the core structure defines a corresponding tab recess configured to receive the retaining tab.

5 . The disc brake assembly of claim 4 , wherein the retaining tab is configured to receive a rivet that mechanically fastens the first wear pad to the core structure.

6 . The disc brake assembly of claim 5 , wherein a second wear pad of the plurality of wear pads does not have a retaining tab.

7 . The disc brake assembly of claim 6 , wherein the first wear pad and the second wear pad abut one another to form a joint, wherein the first wear pad secures the second wear pad to the core structure as a consequence of the first wear pad being fastened to the core structure.

8 . The disc brake assembly of claim 1 , wherein the plurality of wear pads includes a first wear pad and a second wear pad, the first wear pad having a first edge that abuts a second edge of the second wear pad to form a joint, wherein the joint between the first wear pad and the second wear pad results in the first wear pad mechanically securing the second wear pad to the core structure.

9 . The disc brake assembly of claim 8 , wherein the joint comprises a shiplap joint between the first wear pad and the second wear pad.

10 . The disc brake assembly of claim 8 , wherein the first edge of the first wear pad includes a recess in the mounting surface that spans along a portion of the first edge, and wherein the second edge of the second wear pad includes a rail extending along a portion of the second edge and configured to interlink with the recess of the first wear pad.

11 . The disc brake assembly of claim 10 , wherein the first wear pad comprises a retaining tab integral to the first wear pad and protruding from an inner or outer edge of the first wear pad, wherein the retaining tab does not form part of the friction surface, wherein the retaining tab is configured to receive a rivet that mechanically fastens the first wear pad to the core structure, and wherein the second wear pad does not include a retaining tab.

12 . The disc brake assembly of claim 1 , wherein the plurality of wear pads comprises a first plurality of wear pads, the disc brake assembly further comprising a second plurality of wear pads, each of the second plurality of wear pads defining a friction surface and a mounting surface, wherein the mounting surfaces of the second plurality of wear pads are positioned adjacent to, and in contact with, a second major surface of the core structure, wherein the second major surface of the core structure is oppositely oriented from the first major surface and comprises at least one curved ridge or curved channel that curves as the curved ridge or curved channel extends in a radial direction along the second major surface between the inner and outer diameter of the core structure, and wherein the mounting surface of at least one wear pad of the second plurality of wear pads comprises a corresponding curved ridge or curved channel that curves as the corresponding curved ridge or curved channel extends in the radial direction along the mounting surface, wherein the corresponding curved ridge or curved channel is configured to interlink with the at least one curved ridge or curved channel of the second major surface.

13 . The disc brake assembly of claim 1 , wherein the first major surface of the core structure defines at least one mounting rail that spans along an inner or outer diameter of the core structure, and wherein each mounting surface of the plurality of wear pads defines a mounting recess configured to interlink with at least one mounting rail to inhibit radial movement of the plurality of wear pads.

14 . The disc brake assembly of claim 1 , wherein the core structure comprises a first carbon-carbon composite material and the plurality or wear pads comprises a second carbon-carbon composite material, wherein the first carbon-carbon composite material is different from the second carbon-carbon composite material.

15 . A method comprising assembling a brake disc assembly, wherein assembling the brake disc assembly comprises:
mounting a first plurality of wear pads to a core structure,
wherein the core structure defines an inner and outer diameter, the core structure having a first major surface comprising a plurality of curved ridges or curved channels that each curve as the curved ridges or curved channels extend in a radial direction along the first major surface between the inner and outer diameter of the core structure,
wherein each wear pad of the first plurality of wear pads defines a friction surface and a mounting surface, wherein the mounting surfaces of the first plurality of wear pads are positioned adjacent to, and in contact with, the first major surface of the core structure, wherein the mounting surfaces of the plurality of wear pads each comprises at least one corresponding curved ridge or curved channel that curves as the corresponding curved ridge or curved channel extends in the radial direction along the mounting surface, wherein the corresponding curved ridge or curved channel is configured to interlink with a respective curved ridge or curved channel of the plurality of curved ridges or curved channels of the core structure.

16 . The method of claim 15 , wherein a first wear pad of the first plurality of wear pads comprises a retaining tab integral to the f

Assignees

• Honeywell Int Inc

Inventors

• Charles David Lane
• Childers Amanda
• Sutton Ii J Robert

Classifications

• F16D2069/0441

  Mechanical interlocking, e.g. roughened lining carrier, mating profiles on friction material and lining carrier · CPC title

• F16D2065/1356

  interlocking · CPC title

• F16D2200/0052

  Carbon · CPC title

• F16D69/023 Primary

  Composite materials containing carbon and carbon fibres or fibres made of carbonizable material · CPC title

• F16D2250/0084

  Assembly or disassembly · CPC title