Patent Description:
Vehicles, such as aircrafts, may use a wheel brake system that includes a disc stack assembly. For example, the brake system may include a plurality of rotors engaged with a wheel and a plurality of stators interleaved with the rotors. The rotors and wheel are configured to rotate around an axle, while the stators remain rotationally stationary. To decelerate rotational motion of a rotating wheel, the brake system may displace pistons against a pressure plate to squeeze the rotating rotors engaged with the wheel against the stationary stators, therefore producing torque that decelerates the rotational motion of the wheel. In some examples, the rotors may engage with the wheel via rotor drive keys positioned on an interior surface of the wheel. In some such examples, the rotors may define slots configured to receive the rotor drive keys. Examples are disclosed in the <CIT>, <CIT>.

In general, the invention describes articles, systems, and techniques relating to an insert assembly for a brake disc in a wheel brake system of a vehicle. The brake disc has one or more disc slots around the brake disc perimeter (e.g., an inner perimeter and/or an outer perimeter), such as a drive slot configured to receive a rotor drive key of the wheel brake system or a spline slot configured to receive a spline of the wheel brake system. The insert assembly is configured to mechanically couple with the brake disc at the disc slot, e.g., such that some portion of the insert resides within the disc slot of the brake disc. The insert assembly may be configured to help protect the brake disc against, for example, the mechanical stresses borne by the disc slot of the brake disc during braking operations of the wheel brake system.

In examples described herein, the insert assembly includes an insert, a rivet, and a washer. The insert is configured to position with the disc slot. The rivet is configured to extend through the washer and a rivet slot of the insert to secure the insert to the brake disc. The insert assembly is configured such that the brake disc imparts a torque to the rotor drive key or spline via the insert during braking operations of the wheel brake system when the insert is secured to the brake disc by the rivet extending through the rivet slot. The rivet slot is configured to allow motion of the insert in a tangential direction of the brake disc when the brake disc imparts the torque to the rotor drive key or spline such that, for example, the insert may seat more firmly against a torque face of the disc when torque is imparted to the rotor drive key or spline via the insert.

The washer is configured to position between a rivet head of the rivet and the insert when the rivet extends through the washer and a rivet slot. In examples, the rivet head is an orbitally riveted head fabricated using an orbital riveting tool. The washer may be configured to allow for the orbital riveting in a manner which limits and/or substantially prevents deformation of the rivet head into the rivet slot. For example, the washer may be configured to substantially separate the forming or formed rivet head from the rivet slot to substantially prevent the rivet from deforming into the rivet slot during an orbital riveting process.

In an example, an assembly comprises: a rivet defining a rivet head attached to a rivet shank; a washer defining a washer hole; and an insert defining an insert ear configured to cover a surface of a brake disc when the insert positions over a torque face of a slot on a perimeter of the brake disc; wherein the insert ear defines a rivet slot extending through the insert ear, wherein the rivet slot is configured to allow passage of the rivet shank through the rivet slot and into the brake disc to secure the insert to the brake disc, wherein the washer is configured to be positioned between the rivet head and the insert ear when the rivet shank passes through the rivet slot and the washer hole and into the brake disc, and wherein the rivet slot is configured to allow motion of the insert relative to the rivet in a tangential direction of the brake disc when the rivet shank passes through the rivet slot and the washer hole and into the brake disc.

In an example, an assembly comprises: a brake disc defining a first surface on a first side of the brake disc, a second surface on a second side of the brake disc opposite the first side, and a torque face between the first surface and the second surface; an insert configured to be positioned over the torque face, wherein the insert defines a first insert ear configured to cover the first surface and a second insert ear configured to cover the second surface when the insert positions over the torque face, wherein the first insert ear defines a first rivet slot extending through the first insert ear in an axial direction of the brake disc, and wherein the second insert ear defines a second rivet slot extending through the second insert ear in the axial direction of the brake disc; a first washer defining a first washer hole; a second washer defining a second washer hole; and a rivet defining a first rivet head attached to a first end portion of a rivet shank and defining a second rivet head attached to a second end portion of the rivet shank opposite the first end, wherein the rivet shank is configured to pass through the first washer hole, the first rivet slot, the brake disc, the second washer hole, and the second rivet slot, such that the first washer is between the first rivet head and the first insert ear and the second washer is between the second rivet head and the second insert ear, and wherein the first rivet slot and the second rivet slot are configured to allow motion of the insert relative to the rivet in a tangential direction of the brake disc when the rivet shank is passed through the first washer hole, the first rivet slot, the brake disc, the second washer hole, and the second rivet slot.

In an example, a method comprises: covering a torque face defining a slot of a brake disc and a surface of the brake disc with an insert, wherein the insert defines an insert ear covering the surface; and extending a rivet shank of a rivet through a washer hole of a washer, through a rivet slot of the insert ear, and into the brake disc to secure the insert to the brake disc as the insert covers the torque face and the surface of the brake disc, such that the washer is between a rivet head of the rivet and the insert ear, wherein the rivet slot is configured to allow motion of the insert relative to the rivet in a tangential direction of the brake disc when the rivet shank passes through the rivet slot and the washer hole and into the brake disc.

The invention describes articles, systems, and techniques relating to an insert for a brake disc in a wheel brake system of a vehicle. The insert described herein is configured to be mechanically coupled to a brake disc, which may be one of a plurality of brake discs of a brake disc stack of a brake system. The brake disc defines a plurality of disc slots (e.g., a plurality of drive slots and/or a plurality of spline slots) around a brake disc perimeter, and the insert is configured to mechanically couple with the brake disc at the disc slot. For example, the brake disc may include a plurality of drive slots on an outer perimeter of the brake disc, and the insert may be configured to mechanically couple with the brake disc at a drive slot. As another example, the brake disc may include a plurality of spline slots on an inner perimeter of the brake disc, and the insert may be configured to mechanically couple with the brake disc at a spline slot.

The insert is configured such that at least some portion of the insert resides between the disc slot of the brake disc and a rotor drive key or spline extending through the slot when the brake disc is assembled within a brake system. The insert may be configured to protect the brake disc against, for example, the mechanical stresses borne by the disc slot of the brake disc during braking operations of a brake system. For example, the insert may be configured to help distribute the load from the drive key and/or splines to the brake disc and/or to reduce wear on the brake disc.

The insert is configured to mechanically couple to the brake disc in a manner that allows motion of the insert relative to the brake disc in a tangential direction of the brake disc during braking operations of a brake system. For example, the brake disc may be a rotor disc or a stator disc within a disc stack of the braking system. During a braking operation, the disc stack may be compressed, for example by one or more piston and cylinder assemblies, in order to urge the friction surfaces of the disc stack into engagement. The frictional engagement may impart torque via the insert to a rotor drive key extending through a drive slot or spline extending through a spline slot. The insert is configured to mechanically couple to the brake disc to allow tangential motion of the insert relative to the brake disc when the torque is imparted to the rotor drive key or spline via the insert such that, for example, the insert may seat more firmly against a torque face of the disc when torque is imparted to the rotor drive key or spline via the insert.

Disclosed herein is an assembly including an insert, a rivet, and a washer configured to position on a brake disc. The rivet includes a rivet head attached to an end portion of a rivet shank. The insert is configured to position within a disc slot of the brake disc (e.g., a drive slot or a spline slot). The rivet shank is configured to extend through a washer hole of the washer and a rivet slot of the insert to secure the insert to the brake disc. In examples, the rivet extends into the brake disc in an axial direction of the brake disc. The rivet head and/or the rivet slot are configured to position (e.g., seat or trap) the washer between the insert and the rivet head when the rivet shank extends into the brake disc. The rivet slot is configured to allow for the motion of the insert relative to the brake disc and/or the rivet in the tangential direction when torque is imparted through the disc slot via the insert. The assembly is configured such that, when the rivet slot allows tangential motion of the insert, the insert moves relative to the rivet and the washer. In examples, a first side of the insert is slidably engaged with the washer and a second side of the insert opposite the first side is slidably engaged with a surface of the brake disc such that, during tangential motion of the insert, the insert slides between the washer and the brake disc relative to both the washer and the brake disc.

The insert is configured to cover a surface of the brake disc when the insert is positioned within a disc slot. For example, the insert may define an insert ear configured to cover the surface of the brake disc when the insert is positioned within a disc slot. In examples, the insert ear is configured to provide axial support to the insert when the insert is positioned within the disc slot. For example, the insert ear may be configured to engage the disc surface when the insert experiences a force acting in a direction from the insert ear towards the brake disc (e.g., a force in an axial direction of the brake disc). In examples, the insert ear defines the rivet slot.

In examples, the rivet head is an orbitally riveted head fabricated using an orbital riveting tool (e.g., a peen tool). In some examples, the washer is configured to allow for the orbital riveting (and/or another cold forming process) of the rivet head in a manner which limits and/or substantially prevents deformation of the rivet head into the rivet slot during the orbital riveting process. The insert may be positioned within the disc slot, and the rivet shank extended through the washer hole, the rivet slot of the insert, and into the brake disc, prior to fabricating the rivet head at the end of the rivet shank. The rivet head may be fabricated by deforming a portion of the rivet (e.g., an end of the rivet shank) to cause the portion of the rivet to substantially collapse against the washer. The washer may substantially separate the forming or formed rivet head from the rivet slot, limiting and/or substantially preventing the rivet from deforming into the rivet slot. Hence, the washer may reduce and/or limit physical interference between the rivet head and the rivet slot which might otherwise limit and/or substantially prevent motion of the insert relative to the brake disc. Further, the boundary of the washer hole may radially support a portion of the rivet shank immediately adjacent the forming or formed rivet head, limiting and/or substantially preventing expansion of the rivet shank within the insert slot during the orbital riveting process to, for example, reduce and/or limit physical interference between a deformed rivet shank and the rivet slot that might otherwise limit and/or substantially prevent motion of the insert relative to the brake disc. In examples, the rivet is a solid rivet having a substantially solid rivet shank (rather than, e.g., a hollow rivet or semi-tubular rivet), such that the rivet may be considered a solid rivet.

In examples, the rivet slot is a substantially oblong and/or oval shaped slot configured to allow the tangential motion of the insert. For example, the rivet slot may define a first dimension (e.g., first dimension D1 (<FIG>)) in tangential direction of the brake disc and a second dimension (e.g., second dimension D2 (<FIG>)) in a radial direction of the brake disc (or otherwise orthogonal to the first dimension). The first dimension D1 may be configured to allow tangential motion of the insert relative to the rivet and brake disc when the rivet shank extends through the rivet slot and into the brake disc. The first dimension D1 may exceed a cross-sectional dimension of the rivet shank (e.g., a diameter), such that the insert may move relative to the rivet. For example, the first dimension D1 may exceed the cross-sectional dimension of the rivet shank by about <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, or another percentage of the cross-sectional dimension of the rivet shank. The second dimension D2 may be less than the first dimension. For example, the rivet slot may be configured such that the second dimension D2 is slightly larger than the cross-sectional dimension of the rivet shank (e.g., by about <NUM>%, <NUM>,%, <NUM>%, or another percentage of the cross-sectional dimension of the rivet shank) while remaining less than the first dimension D1.

In some examples, the rivet slot is configured to allow the insert to pivot around the rivet shank to at least some degree when torque is imparted by the disk slot to a rotor drive key or spline via the insert. Pivoting of the insert around the rivet shank may allow the insert to seat more firmly and conform more effectively against the disc when the torque is imparted. This may allow the insert to distribute forces (e.g., reaction forces imparted to the disc from a rotor drive key or spline) more effectively over a torque face of the brake disc, reducing stresses generated on the brake disc during a braking operation. As used herein, when the rivet slot is configured to allow the insert to pivot around the rivet shank, this may mean rivet slot is configured such that the insert may rotate to some degree with respect to the brake disc when the rivet shank extends through the rivet slot and into the brake disc. For example, the insert may rotate with respect to the brake disc around a rotation axis parallel to the axial direction of the brake disc, such that the rotation defines an angle of rotation in a plane defined by the tangential direction of the brake disc and the radial direction of the brake disc.

In examples, the rivet slot is configured to allow for tangential motion of the insert relative to the rivet and the brake disc in a manner reducing and/or substantially limiting loading (e.g., shear loading) of the rivet shank. For example, the insert may include a body section comprising a drive face configured to engage a rotor drive key or spline when the brake disc imparts a torque to the rotor drive key or spline. The body section may include a back face opposite the drive face configured to engage the brake disc (e.g., a torque face defining the disc slot) when the brake disc imparts the torque, such that the brake disc imparts the torque via the insert. The insert (e.g., the rivet slot) may be configured such that the back face engages the brake disc without the rivet shank engaging the rivet slot when the insert moves tangentially, such that the rivet slot is substantially prevented from imparting a force (e.g., a shear force) against the rivet shank as the brake disc imparts the torque via the insert. This may reduce and/or substantially eliminate shear forces imparted to the rivet, such that the rivet (e.g., the rivet shank) remains substantially unloaded by the impartation of torque from the brake disc to the rotor drive key or spline.

For example (e.g., when the insert is secured to the brake disc by the rivet), the insert is configured to translate a first distance (e.g., first distance DS1 (<FIG>)) to cause the back face to engage the brake disc, and the rivet slot is configured such that the rivet shank is separated from a portion of the boundary of the rivet slot by a second distance (e.g., second distance DS2 (<FIG>)) greater than the first distance. In some examples (e.g., when the insert is secured to the brake disc by the rivet), the insert is configured such that the rivet is separated by a third distance in the tangential direction of the brake disc (e.g., third distance DS3 (<FIG>)) when the back face engages the brake disc.

In examples, the insert defines a gap configured to receive the brake disc when the insert positions within the disc slot and covers the torque face of the disc slot. The insert may be configured such that the brake disc constrains displacement of the insert in the axial direction of the brake disc when the insert receives the brake disc. For example, a brake disc may include a first side and a second side displaced from the first side in an axial direction of the brake disc. The first and second sides may include, for example, friction surfaces of the brake disc configured to engage a friction surface of an adjacent brake disc during a braking operation. The disc slot (e.g., a drive slot on an outer perimeter or a spline slot on an inner perimeter) may extend in the axial direction substantially between the first side and the second side.

The insert (e.g., an insert ear) may be configured to cover a first surface on the first side and cover a second surface on the second side when the insert receives the brake disc. In some examples, the insert slidably engages the first surface and the second surface, such that the insert can substantially slide over the first surface and the second surface when the insert moves in the tangential direction of the brake disc. The insert may be configured such that the first surface and/or second surface engages the insert when the insert experiences a force in an axial direction of the brake disc, such that the brake disc substantially abuts the insert when the insert receives the brake disc, such that the brake disc constrains displacement of the insert in the axial direction of the brake disc.

The insert may be configured such that the rivet substantially constrains displacement of the insert in a radial direction of the brake disc when the rivet extends through the rivet slot and into the brake disc. The insert may be configured such that the rivet encounters the rivet slot when the insert experiences a force in a radial direction of the brake disc, such that the rivet and/or rivet slot constrains displacement of the insert in the radial direction of the brake disc. For example, the insert may be configured such that the rivet slot limits displacement of the insert in the radial direction to a distance of about the second dimension D2 (<FIG>).

As used herein, an axial direction of a brake disc means a direction substantially parallel (e.g., parallel or nearly parallel to the extent permitted by manufacturing tolerances) to a disc axis A (<FIG>) about which the brake disc is configured to rotate. A radial direction of the brake disc means a direction substantially parallel (e.g., parallel or nearly parallel to the extent permitted by manufacturing tolerances) to a radial distance in a cylindrical coordinate system when the disc axis A is the cylindrical axis in the cylindrical coordinate system. A tangential direction of the brake disc means a direction perpendicular to the axial direction and perpendicular to the radial direction.

Hence, the assembly described herein includes an insert is configured to mechanically couple to the brake disc in a manner that allows motion of the insert relative to the brake disc (and/or a rivet) in a tangential direction of the brake disc during braking operations of a brake system such that, for example, the insert may seat more firmly against a torque face of the disc when torque is imparted to the rotor drive key or spline via the insert. A rivet shank is configured extend through a washer hole of a washer and a rivet slot of the insert to secure the insert to the brake disc. In some examples, the rivet slot is a substantially elongated (e.g., oblong and/or oval shaped) slot configured to allow the tangential motion of the insert. The assembly may be configured such that, when the rivet slot allows tangential motion of the insert, the insert moves relative to the rivet and the washer. In examples, the washer is configured to allow for a cold forming process (e.g., orbital riveting) of a rivet head on the rivet shank in a manner which limits and/or substantially prevents deformation of the rivet head into the rivet slot during the orbital riveting process.

<FIG> is a perspective view illustrating an example wheel <NUM>. In some examples, wheel <NUM> is a part of an aircraft vehicle. In other examples, wheel <NUM> may be a part of any other vehicle, such as, for example, any land vehicle or other vehicle. In the example shown in <FIG>, wheel <NUM> includes a wheel rim <NUM> defining an exterior surface <NUM> and interior surface <NUM>. Wheel rim <NUM> includes tubewell <NUM> and wheel hub <NUM>. In some examples, interior surface <NUM> may include an inner diameter of tubewell <NUM> of wheel <NUM>. For example, in some cases, interior surface <NUM> may be referred to as an inner diameter surface of wheel <NUM>. Interior surface <NUM> and wheel hub <NUM> may define a wheel cavity <NUM> (e.g., a volume) between interior surface <NUM> and wheel hub <NUM>. In some examples, a tire (not shown) may be mounted on exterior surface <NUM> of rim <NUM>. Wheel <NUM> may include an inboard bead seat <NUM> and an outboard bead seat <NUM> configured to retain a tire on exterior surface <NUM> of rim <NUM>. In examples, wheel <NUM> may comprise an inboard section <NUM> (e.g., including inboard bead seat <NUM>) and an outboard section <NUM> (e.g., including outboard bead seat <NUM>). Wheel <NUM> is configured to rotate around an axis of rotation AW. An axial direction AW1 of wheel <NUM> is parallel to the axis of rotation AW.

Wheel <NUM> includes a plurality of rotor drive keys <NUM> on interior surface <NUM> of wheel <NUM>, such as rotor drive key <NUM> and rotor drive key <NUM>. In some examples, each rotor drive key of the plurality of rotor drive keys <NUM> extends in the axial direction AW1 of wheel <NUM> (e.g., in a direction parallel to the axis of rotation A). The plurality of rotor drive keys <NUM> ("rotor drive keys <NUM>") and interior surface <NUM> are configured to be substantially stationary with respect to each other, such that when wheel <NUM> (and interior surface <NUM>) rotates around axis of rotation AW, each of the rotor drive keys (e.g., rotor drive keys <NUM>, <NUM>) translates over a closed path around axis AW. Consequently, when wheel <NUM>, interior surface <NUM>, and rotor drive keys <NUM> are rotating around axis of rotation AW, a force on one or more of rotor drive keys <NUM> opposing the direction of rotation acts to slow or cease the rotation. Rotor drive keys <NUM> may be configured to receive a torque from a brake system (e.g., brake system <NUM> (<FIG>)) configured to reduce and/or cease a rotation of wheel <NUM>. Rotor drive keys <NUM> may be integrally formed with interior surface <NUM>, or may be separate from and mechanically affixed to interior surface <NUM>.

<FIG> is a schematic cross-sectional view illustrating wheel <NUM> and an example brake system <NUM>. Wheel <NUM> includes wheel rim <NUM>, exterior surface <NUM>, interior surface <NUM>, wheel cavity <NUM>, wheel hub <NUM>, inboard bead seat <NUM>, outboard bead seat <NUM>, inboard section <NUM>, outboard section <NUM>, and rotor drive key <NUM>. <FIG> illustrates wheel rim <NUM> as a split rim wheel with lug bolt <NUM> and lug nut <NUM> connecting inboard section <NUM> and outboard section <NUM>, however wheel rim <NUM> may utilize other configurations (e.g., a unified wheel rim) in other examples. Wheel <NUM> and brake system <NUM> is shown and described to provide context to the example inserts described here. The inserts described herein, however, may be used with any suitable wheel and brake system in other examples.

Wheel <NUM> is configured to rotate about axis AW extending through an axial assembly <NUM>. Axial assembly <NUM> is figured to support wheel <NUM> while allowing wheel <NUM> to rotate around axis A using bearing <NUM> and bearing <NUM>. For example, bearings <NUM>, <NUM> may define a substantially circular track around axial assembly <NUM>. A torque tube <NUM> is coupled to axial assembly <NUM> (e.g., via bolts <NUM>, <NUM>), such that torque tube <NUM> remains substantially stationary when wheel <NUM> rotates around axial assembly <NUM> and axis A. Torque tube <NUM> may at least partially surround an exterior of axial assembly <NUM>. Axial assembly <NUM> may be mechanically coupled to a structure (e.g., a strut) attached to a vehicle.

In the example shown in <FIG>, brake system <NUM> is positioned within wheel <NUM> and is configured to engage torque tube <NUM> and rotor drive key <NUM>. Brake system <NUM> is configured to generate a torque to oppose a rotation of wheel <NUM> around axis AW and transfer the torque to rotor drive key <NUM>, reducing and/or eliminating the rotation of wheel <NUM> around axis AW. Brake system <NUM> includes a disc stack <NUM> which includes one or more brake discs, such as one or more rotor discs (e.g., rotor discs <NUM>, <NUM>, <NUM>, <NUM>) and/or one or more stator discs (e.g., stator discs <NUM>, <NUM>, <NUM>). Rotor discs <NUM>, <NUM>, <NUM>, <NUM>, and/or stator discs <NUM>, <NUM>, <NUM>, may have any suitable configuration. For example, rotor discs <NUM>, <NUM>, <NUM>, <NUM> and/or stator discs <NUM>, <NUM>, <NUM> can each be substantially annular discs surrounding axial assembly <NUM>. Stator discs <NUM>, <NUM>, <NUM> are coupled to torque tube <NUM> via spline <NUM> and remain rotationally stationary with respect to torque tube <NUM> (and axial assembly <NUM>) as wheel <NUM> rotates.

Rotor discs <NUM>, <NUM>, <NUM>, <NUM> are rotationally coupled to rotor drive key <NUM> and interior surface <NUM> and rotate substantially synchronously with wheel <NUM> around axis A. For example, rotor drive key <NUM> may be configured to extend through a drive slot on a perimeter (e.g., an outer perimeter) of one or more of rotor discs <NUM>, <NUM>, <NUM>, <NUM> to cause rotor discs <NUM>, <NUM>, <NUM>, <NUM> to rotate substantially synchronously with wheel <NUM>. Spline <NUM> may be configured to extend through a spline slot on a perimeter (e.g., an inner perimeter) of one or more of stator discs <NUM>, <NUM>, <NUM> to cause stator discs <NUM>, <NUM>, <NUM> remain rotationally stationary with respect to torque tube <NUM> (and axial assembly <NUM>) as wheel <NUM> rotates. Disc stack <NUM> may include any number of rotor discs and stator discs.

Rotor discs <NUM>, <NUM>, <NUM>, <NUM>, and/or stator discs <NUM>, <NUM>, <NUM>, may be configured to provide opposing friction surfaces for braking a vehicle, such as an aircraft. Compression of disc stack <NUM> (e.g., between pressure plate <NUM> and backing plate <NUM>) may bring the opposing friction surfaces into contact, generating shearing forces between the rotor discs rotating substantially synchronously with wheel <NUM> and the stator discs remaining substantially stationary with respect to torque tube <NUM>. The shearing forces may cause a rotor disc (e.g., rotor discs <NUM>, <NUM>, <NUM>, <NUM>) engaged with rotor drive key <NUM> to impart a torque on rotor drive key <NUM> opposing the rotation of wheel <NUM>. The rotor disc may impart the opposing torque to rotor drive key <NUM> using the drive slot through which rotor drive key <NUM> extends. The shearing forces may cause a stator disc (e.g., stator discs <NUM>, <NUM>, <NUM>) engaged with spline <NUM> to impart a torque on spline <NUM> to counteract the torque imposed on rotor drive key <NUM>. The stator disc may impart the torque to spline <NUM> using the spline slot through which spline <NUM> extends.

In examples, a brake disc of disc stack <NUM> includes an insert positioned within a disc slot (e.g., a rotor drive slot or a spline slot). The insert may be configured such that some portion of the insert resides within the disc slot of the brake disc and is positioned between the disc slot and the brake disc. The insert may be configured to allow the brake disc to translate in a direction substantially parallel to axis AW when disc stack <NUM> is compressed. The insert may be configured to help protect the brake disc against, for example, the mechanical stresses borne by the disc slot of the brake disc when disc stack <NUM> is compressed and rotor discs <NUM>, <NUM>, <NUM>, <NUM> impart a torque to rotor drive key <NUM> and/or stator discs <NUM>, <NUM>, <NUM> impart a torque to spline <NUM>. In examples, the insert is configured to allow for movement of the insert in a tangential direction of the brake disc when the brake disc imparts a torque to rotor drive key <NUM> or spline <NUM> such that, for example, the insert may seat more firmly against a torque face of the disc when torque is imparted to the rotor drive key or spline via the insert.

An actuator <NUM> is configured to compress disc stack <NUM> to bring the opposing friction surfaces of rotor discs <NUM>, <NUM>, <NUM>, <NUM> into contact with friction surfaces of stator discs <NUM>, <NUM>, <NUM>. Actuator <NUM> may be configured to cause a piston <NUM> to translate relative to a body <NUM> of actuator <NUM> to compress disc stack <NUM>. Actuator <NUM> may cause piston <NUM> to translate using any suitable method. In some examples, actuator <NUM> is configured to cause translation of piston <NUM> by supplying and/or venting a pressurized hydraulic fluid to or from a piston chamber. In addition or instead, in some examples, actuator <NUM> is configured to cause piston <NUM> to translate through a motion (e.g., a rotary motion) generated by an electric motor.

Wheel <NUM> may be used with any variety of private, commercial, or military aircraft or other type of vehicle. Wheel <NUM> may be mounted to a vehicle via, for example, axial assembly <NUM>, or some other appropriate arrangement to allow wheel <NUM> to rotate around axis AW. Axial assembly <NUM> may be mounted on a strut of a landing gear (not shown) or other suitable component of a vehicle to connect wheel <NUM> to the vehicle. Wheel <NUM> may rotate around axis A and axial assembly <NUM> to impart motion to the vehicle. Wheel <NUM> is shown and described to provide context to the brake system described herein, however the brake system described herein may be used with any suitable wheel assembly in other examples.

<FIG> is a diagram illustrating an example brake disc <NUM>, which is an example of one or more brake discs within disc stack <NUM> (<FIG>). For example, brake disc <NUM> may be an example of one or more of rotor discs <NUM>, <NUM>, <NUM>, <NUM> (<FIG>). Brake disc <NUM> defines a central aperture <NUM> extending through brake disc <NUM>. Central aperture <NUM> may be defined by an inner perimeter <NUM> of disc <NUM> ("disc inner perimeter <NUM>"). Central aperture <NUM> is configured to allow rotation of brake disc <NUM> around an axis A illustrated perpendicular to the page. Brake disc <NUM> further defines a plurality of drive slots around an outer perimeter <NUM> of brake disc <NUM> ("disc outer perimeter <NUM>"). The plurality of drive slots comprises, for example, disc slot <NUM> and disc slot <NUM>, as well as others similarly depicted. Brake disc <NUM> further includes friction surface <NUM> on a first side <NUM> of brake disc <NUM> ("disc first side <NUM>"), and may include a second friction surface (not shown) on a second side <NUM> of brake disc <NUM> ("disc second side <NUM>") opposite disc first side <NUM>. Although depicted as a drive slot in <FIG> for reference, disc slot <NUM> may be, for example, a drive slot defined on disc outer perimeter <NUM>, or a spline slot defined on disc inner perimeter <NUM>.

Brake disc <NUM> is configured to rotate substantially around axis A. A first axial direction A1 of brake disc <NUM> is a first vector coincident with axis A and having a direction perpendicular to and into the page. A second axial direction A2 of brake disc <NUM> is a second vector coincident with axis A and having a direction perpendicular to and out of the page. A radial axis R intersects and is perpendicular to the axis A. First radial direction R1 of brake disc <NUM> is a third vector coincident with radial axis R and having a direction toward axis A. Second radial direction R2 is a fourth vector having a direction opposite the third vector. A first tangential direction T1 of brake disc <NUM> is a fifth vector defining a <NUM> degree angle from first radial direction R1 and first axial direction A1 in a right-handed coordinate frame. A second tangential direction T2 is a sixth vector having a direction opposite the third vector.

In <FIG>, the radial direction R is illustrated as defining an angle θ with a reference axis AZ. The radial direction R may be oriented with respect to brake disc <NUM> to define any angle θ with reference axis AZ. For example, a specific radial direction R may define an angle θ causing the radial direction R to intersect disc slot <NUM>, disc slot <NUM>, any other disc slot on brake disc <NUM>, any point on disc outer perimeter <NUM>, or any point on brake disc <NUM>. The inward radial direction R1, the outward radial direction R2, the first tangential direction T1, and the second tangential direction T2 may be defined with respect to the specific radial direction R. In some examples, axis A is substantially parallel to axis AW of wheel <NUM> (e.g., parallel or nearly parallel to the extent permitted by manufacturing tolerances).

As used herein, the first axial direction A1, the first radial direction R1, the first tangential direction T1, the second axial direction A2, the second radial direction R2, and/or the second tangential direction T2, may refer to directions relative to a fixed point on brake disc <NUM> and defined by the orientation of brake disc <NUM>. In some examples, the first axial direction A1, the first radial direction R1, the first tangential direction T1, the second axial direction A2, the second radial direction R2, and/or the second tangential direction T2, refer to directions relative to a fixed point on an insert assembly and defined by an orientation of the insert assembly, with the directions relative to the fixed point on the insert assembly corresponding to the directions of the first axial direction A1, the first radial direction R1, the first tangential direction T1, the second axial direction A2, the second radial direction R2, and/or the second tangential direction T2 which would result if the insert assembly were secured to brake disc <NUM>. For example, when an insert assembly is displaced from (e.g., not secured to) brake disc <NUM>, the first axial direction A1, the first radial direction R1, the first tangential direction T1, the second axial direction A2, the second radial direction R2, and/or the second tangential direction T2, may refer to directions relative to the orientation of the insert assembly that would result were the insert assembly to be secured to brake disc <NUM>.

The plurality of disc slots such as <NUM>, <NUM> may be to accommodate the extension of a plurality of drive keys, such as the plurality of rotor drive keys <NUM> (<FIG>), through disc slots <NUM>, <NUM>. For example, <FIG> illustrates a portion of a rotor drive key <NUM> extending through disc slot <NUM>. Rotor drive key <NUM> may be a rotor drive key within the plurality of rotor drive keys <NUM> (<FIG>), such as rotor drive key <NUM> (<FIG>). Disc slot <NUM> may be configured such that rotor drive key <NUM> extends through disc slot <NUM> in an axial direction of brake disc <NUM> (e.g., a direction substantially parallel to axis A, e.g., parallel or nearly parallel to the extent permitted by manufacturing tolerances). One or more of the drive slots (e.g., a subset of the drive slots or all of the drive slots) defined by brake disc <NUM> may have a portion of a respective rotor drive key extending through the drive slot in a manner similar to that depicted for disc slot <NUM> and rotor drive key <NUM>.

Rotor drive key <NUM> is configured such that, when rotor drive key <NUM> rotates synchronously with a wheel (e.g., wheel <NUM> (<FIG> and <FIG>), rotor drive key imparts a force on brake disc <NUM> in a tangential direction of brake disc <NUM> (e.g., in first tangential direction T1 or second tangential direction T2) to cause rotation of brake disc <NUM> around axis A. Brake disc <NUM> is configured such that, when a shearing force generates on friction surface <NUM> (e.g., due to frictional engagement with a stator disc), disc slot <NUM> imparts a force on rotor drive key <NUM> (e.g., in first tangential direction T1 or second tangential direction T2) which opposes the synchronous rotation of rotor drive key <NUM> with wheel <NUM>.

In some examples, e.g., when disc slots <NUM>, <NUM> are defined on disc inner perimeter <NUM> of brake disc <NUM>, disc slots <NUM>, <NUM> may be configured to accommodate the extension of one or more splines, such as one or more of spline <NUM> (<FIG>). For example, disc slots <NUM>, <NUM> may be configured such that spline <NUM> extends through disc slot <NUM> in an axial direction of brake disc <NUM>. Brake disc <NUM> may be configured such that, when a shearing force generates on friction surface <NUM> (e.g., due to frictional engagement with a rotating rotor disc), disc slot <NUM> imparts a force on spline <NUM> (e.g., in first tangential direction T1 or second tangential direction T2).

One or more (e.g., all) of the plurality of drive slots defined by brake disc <NUM>, including disc slots <NUM>, <NUM>, may be reinforced by an insert assembly, such as insert assembly <NUM> including insert <NUM> within disc slot <NUM>. While insert assembly <NUM> and disc slot <NUM> are primarily referred to in the description of <FIG> as well as other figures, the description of insert assembly <NUM> and disc slot <NUM> may apply to the other disc slots and drive inserts of brake disc <NUM> and other brake discs described herein. Additionally, while brake disc <NUM> is primarily referred to in the description of <FIG> as well as other figures, the insert assemblies described herein may also be utilized on a stator slot of a stator brake disc, such as one or more of stator brake discs <NUM>, <NUM>, <NUM> (<FIG>). For example, the insert assemblies described herein be utilized on a stator slot of an inner perimeter of a brake disc (e.g., stator discs <NUM>, <NUM>, <NUM>) similar to disc inner perimeter <NUM>.

Insert assembly <NUM> is configured to minimize or even eliminate the extent to which rotor drive key <NUM> engages directly with a surface of brake disc <NUM> during a braking operation. Insert assembly <NUM> (e.g., insert <NUM>) may be configured to provide a sliding and a bearing surface to act against rotor drive key <NUM> during braking operations, such that insert assembly <NUM> minimizes or even eliminates the engagement. Insert assembly <NUM> is configured to allow for movement of insert <NUM> in a tangential direction of the brake disc (e.g., in the first tangential direction T1 and/or the second tangential direction T2) when brake disc <NUM> imparts a torque to rotor drive key <NUM>, or when brake disc <NUM> imparts a torque to a spline (e.g., spline <NUM> (<FIG>)). Insert assembly <NUM> may be configured to help protect brake disc <NUM> against, for example, the mechanical stresses borne by disc slot <NUM> of brake disc <NUM> when brake disc <NUM> imparts a torque to rotor drive key <NUM> or spline <NUM>.

<FIG> illustrate an example insert assembly <NUM> comprising an insert <NUM>, a rivet <NUM>, and a washer <NUM>. Insert assembly <NUM> is configured to position within a disc slot <NUM> of brake disc <NUM>. <FIG> is an exploded view, showing insert <NUM>, rivet <NUM>, and washer <NUM> displaced from brake disc <NUM>, with a first axial direction A1 parallel to axis A (<FIG>) and a second axial direction A2 parallel to axis A and opposite first axial direction A1 illustrated for reference, along with first radial direction R1, second radial direction R2, first tangential direction T1, and second tangential direction T2. <FIG> is a schematic plan view of insert assembly <NUM> positioned within disc slot <NUM>, with second axial direction A2 perpendicular to and proceeding out of the page, first axial direction A1 (not shown) perpendicular to and proceeding in to the page, and first radial direction R1, second radial direction R2, first tangential direction T1, and second tangential direction T2 parallel to the page. <FIG> is a cross-sectional top view of insert assembly <NUM> positioned within disc slot <NUM>, with the cross-section taken over the cutting plane illustrated as B-B' in <FIG>. In <FIG>, second radial direction R2 is perpendicular to and proceeds out of the page, first radial direction R1 (not shown) is perpendicular to and proceeds in to the page, and first axial direction A1, second axial direction A2, first tangential direction T1, and second tangential direction T2 are parallel to the page.

Insert <NUM> is configured to position within disc slot <NUM> such that at least some portion of insert <NUM> resides between disc slot <NUM> and a rotor drive key or a spline when the rotor drive key or the spline extends through disc slot <NUM> in an axial direction A (<FIG>) of brake disc <NUM>. In examples, disc slot <NUM> is bounded at least in part by a first torque face <NUM> and a second torque face <NUM> facing first torque face <NUM>. Insert <NUM> is configured to reside between first torque face <NUM> and/or second torque face <NUM> when insert <NUM> is received within disc slot <NUM>. In some examples, insert <NUM> is configured such that brake disc <NUM> imparts a torque to a rotor drive key or spline via insert <NUM> when insert <NUM> is positioned within disc slot <NUM>. For example, insert <NUM> may include a body section <NUM> defining a drive face <NUM> and a back face <NUM> opposite the drive face <NUM>. In examples, at least some portion of body section <NUM> separates drive face <NUM> and back face <NUM>. Drive face <NUM> may be configured to engage a rotor drive key or spline when insert <NUM> is positioned in disc slot <NUM> and brake disc <NUM> imparts a torque to the rotor drive key or spline. Back face <NUM> may be configured to engage first torque face <NUM> when brake disc <NUM> imparts the torque to the rotor drive key or spline, such that the brake disc <NUM> imparts the torque to the rotor drive key or spline via insert <NUM>.

First torque face <NUM> and/or second torque face <NUM> may define some portion of disc slot <NUM>. First torque face <NUM> and/or second torque face <NUM> may be configured to bear a tangential force (e.g., in the first tangential direction T1 or in the second tangential direction T2) imparted by a rotor drive key or spline during a braking operation. First torque face <NUM> and/or second torque face <NUM> may have any suitable orientation relative to the axial directions A1, A2, the radial directions R1, R2, and/or the tangential directions T1, T2. In some examples, first torque face <NUM> and/or second torque face <NUM> slants with respect to at least the first radial direction R1, such that a vector parallel to first torque face <NUM> or second torque face <NUM> defines a slope ΔR1/ΔT1, where ΔR1 is the absolute value of a displacement in the first radial direction R1 and ΔT1 is the absolute value of a displacement in a direction parallel to the first tangential direction T1. In examples, first torque face <NUM> and/or second torque face <NUM> are non-parallel (e.g., slanted with respect to) a plane defined by the axial directions A1, A2 and the radial directions R1, R2 (non-parallel manufacturing (e.g., non-parallel or nearly non-parallel to the extent permitted by manufacturing tolerances).

Insert <NUM> is configured to cover a first surface <NUM> of brake disc <NUM> ("first disc surface <NUM>") when insert <NUM> is positioned within disc slot <NUM>. In examples, first disc surface <NUM> is a portion of disc first side <NUM>. Insert <NUM> may define an insert ear <NUM> configured to cover first disc surface <NUM> when insert <NUM> is positioned within disc slot <NUM>. In examples, insert ear <NUM> is configured to provide axial support to insert <NUM> when insert <NUM> is positioned within disc slot <NUM>. For example, insert ear <NUM> may be configured to engage (or remain engaged with) first disc surface <NUM> when insert <NUM> experiences a force acting in a direction from insert ear <NUM> towards brake disc <NUM> (e.g., a force in the first axial direction A1). Insert ear <NUM> may be configured such that first disc surface <NUM> imparts a reaction force on insert <NUM> that opposes the force acting in the direction from insert ear <NUM> toward brake disc <NUM>, such that movement of insert <NUM> in the first axial direction A1 is substantially limited and/or prevented. In some examples, insert ear <NUM> is configured to cover first disc surface <NUM> when insert <NUM> (e.g., back face <NUM>) covers first torque face <NUM>. In some examples, insert ear <NUM> extends from body section <NUM> in a substantially tangential direction of brake disc <NUM> (e.g., in the second tangential direction T2) when insert <NUM> is positioned within disc slot <NUM>. In examples, first disc surface <NUM> is adjacent disc slot <NUM> and/or first torque face <NUM>.

In some examples, insert <NUM> is configured to cover a second surface <NUM> of brake disc <NUM> ("second disc surface <NUM>") when insert <NUM> is positioned within disc slot <NUM>. In examples, insert <NUM> includes a second insert ear <NUM> configured to cover second disc surface <NUM>. In examples, second insert ear <NUM> is configured to cover second disc surface <NUM> when insert ear <NUM> covers first disc surface <NUM> and/or body section <NUM> covers first torque face <NUM>. Second insert ear <NUM> may be configured to engage second disc surface <NUM> when insert <NUM> experiences a force acting substantially in the second axial direction A2. Second insert ear <NUM> may be configured such that second disc surface <NUM> imparts a reaction force on insert <NUM> that opposes the force acting substantially in the second axial direction A2, such that movement of insert <NUM> in the second axial direction A2 is substantially limited and/or prevented. In examples, second insert ear <NUM> is configured to cover second disc surface <NUM> when insert <NUM> (e.g., back face <NUM>) covers first torque face <NUM>. In examples, second insert ear <NUM> extends from body section <NUM> in a substantially tangential direction of brake disc <NUM> (e.g., in the second tangential direction T2) when insert <NUM> is positioned within disc slot <NUM>. In examples, second disc surface <NUM> is adjacent disc slot <NUM> and/or first torque face <NUM>. In some examples, first torque face <NUM> is substantially between second disc surface <NUM> and first disc surface <NUM>.

Insert <NUM> includes a rivet slot <NUM> configured to allow passage of rivet <NUM> (e.g., a rivet shank <NUM>) through insert <NUM> to secure insert <NUM> to brake disc <NUM>. In examples, insert ear <NUM> defines rivet slot <NUM>. Washer <NUM> is configured to position between a rivet head <NUM> of rivet <NUM> and insert <NUM> when rivet <NUM> secures insert <NUM> to brake disc <NUM>. For example, washer <NUM> may define a washer hole <NUM> configured to allow passage of rivet shank <NUM> through washer hole <NUM>. Rivet shank <NUM> may be configured to pass through washer hole <NUM>, pass through rivet slot <NUM>, and extend into brake disc <NUM> to secure insert <NUM> to brake disc <NUM>. In examples, rivet shank <NUM> is configured to insert into brake disc <NUM> via a rivet hole <NUM> in brake disc <NUM>. In examples, rivet <NUM> and/or rivet hole <NUM> are configured such that motion of insert <NUM> relative to brake disc <NUM> (e.g., in a tangential direction of brake disc <NUM>) causes motion of insert <NUM> relative to rivet <NUM> when rivet <NUM> is inserted into rivet hole <NUM>. In some examples, rivet <NUM> and/or rivet hole <NUM> are configured such that rivet <NUM> is substantially stationary relative to brake disc <NUM> when rivet <NUM> inserts into brake disc <NUM> via rivet hole <NUM>.

Washer hole <NUM> may be configured (e.g., dimensioned) to prevent passage of rivet head <NUM> through washer hole <NUM> when rivet <NUM> (e.g., rivet shank <NUM>) extends through washer hole <NUM>, extends through rivet slot <NUM>, and extends into brake disc <NUM>. In examples, rivet <NUM> (e.g., rivet shank <NUM> and/or rivet head <NUM>) is configured to remain substantially stationary with respect to brake disc <NUM> when rivet <NUM> inserts into rivet hole <NUM> (e.g., remain substantially stationary with respect to brake disc <NUM> when insert <NUM> moves relative to brake disc <NUM> in the tangential direction of brake disc <NUM>). Washer <NUM> may be configured to remain substantially stationary with respect to brake disc <NUM> when rivet <NUM> (e.g., rivet shank <NUM>) extends through washer hole <NUM> and inserts into rivet hole <NUM>.

Rivet slot <NUM> is configured to allow motion of insert <NUM> in a tangential direction of brake disc <NUM> (e.g., in the first tangential direction T1 and/or second tangential direction T2) when insert <NUM> (e.g., drive face <NUM>) engages a rotor drive key or spline extending through disc slot <NUM> and when insert <NUM> is connected to brake disc <NUM> via rivet <NUM>. For example, when a braking operation causes brake disc <NUM> to cause motion of insert <NUM> relative to the rotor drive key or spline extending through disc slot <NUM>, rivet slot <NUM> may be configured such that a resulting engagement of insert <NUM> (e.g., drive face <NUM>) and the rotor drive key or spline causes tangential motion of insert <NUM> relative to brake disc <NUM>. The tangential motion of insert <NUM> allowed by rivet slot <NUM> may cause insert <NUM> to engage brake disc <NUM> (e.g., cause back face <NUM> to engage first torque face <NUM>). The engagement of back face <NUM> with brake disc <NUM> as drive face <NUM> engages the rotor drive key or spline causes brake disc <NUM> to impart a torque to the rotor drive key or spline via insert <NUM>. In examples, rivet slot <NUM> is configured to allow motion of insert <NUM> in a tangential direction of brake disc <NUM> relative to rivet <NUM> and/or washer <NUM> (e.g., when rivet shank <NUM> extends into brake disc <NUM> via rivet hole <NUM>).

For example, <FIG> illustrates a schematic plan view of a portion of insert assembly <NUM> positioned within disc slot <NUM>, with second axial direction A2 perpendicular to and proceeding out of the page, first axial direction A1 (not shown) perpendicular to and proceeding in to the page, and first radial direction R1, second radial direction R2, first tangential direction T1, and second tangential direction T2 parallel to the page. Washer <NUM> and rivet <NUM> are depicted as transparent and illustrated with dashed lines. Rivet shank <NUM> extends through washer hole <NUM>, rivet slot <NUM>, and into brake disc <NUM>. Washer <NUM> is positioned between rivet head <NUM> and insert <NUM>. Insert ear <NUM> defines rivet slot <NUM>. Insert <NUM> (e.g., insert ear <NUM>) may define a boundary <NUM> of rivet slot <NUM> ("slot boundary <NUM>") surrounding at least some portion of rivet slot <NUM>. In examples, slot boundary <NUM> defines rivet slot <NUM> such that rivet slot <NUM> extends through insert <NUM> (e.g., insert ear <NUM>) in an axial direction of brake disc <NUM> (e.g., in the first axial direction A1 and/or the second axial direction A2).

Rivet slot <NUM> defines a first dimension D1 in a substantially tangential direction of brake disc <NUM> (e.g., in the first tangential direction T1 and/or the second tangential direction T2). First dimension D1 may be configured to allow tangential motion of insert <NUM> relative to rivet <NUM>, washer <NUM>, and/or brake disc <NUM> when rivet shank <NUM> extends through rivet slot <NUM> and into brake disc <NUM>. In examples, rivet slot <NUM> is elongated such that first dimension D1 exceeds a cross-sectional dimension (e.g., a diameter) of rivet shank <NUM>. Rivet slot <NUM> may be configured such that insert <NUM> may move relative to rivet <NUM>, washer <NUM>, and/or brake disc <NUM> when a rotor drive key or a spline extending through disc slot <NUM> imparts a force on insert <NUM> in a tangential direction of brake disc <NUM>. For example, first dimension D1 may exceed the cross-sectional dimension of rivet shank <NUM> by about <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, or another percentage of the cross-sectional dimension of rivet shank <NUM>.

Rivet slot <NUM> defines a second dimension D2 in a substantially radial direction of brake disc <NUM> (e.g., in the first radial direction R1 and/or the second radial direction R2). Second dimension D2 may be substantially perpendicular to first dimension D1 (e.g., perpendicular or nearly perpendicular to the extent permitted by manufacturing tolerances). In examples, second dimension D2 is less than first dimension D1. In examples, rivet slot <NUM> is configured such that at least second dimension D2 provides radial support to insert <NUM> when insert <NUM> positioned within disc slot <NUM>. For example, rivet slot <NUM> (e.g., slot boundary <NUM>) may be configured to engage rivet <NUM> when insert <NUM> experiences a force acting in a direction from insert <NUM> toward brake disc <NUM> and/or a force acting in a direction from brake disc <NUM> toward insert <NUM> (e.g., a force in the first radial direction R1 and/or a force in the second radial direction R2). Rivet slot <NUM> may be configured such that slot boundary <NUM> imparts a reaction force on insert <NUM> that opposes the force acting in the direction acting in the direction from insert <NUM> toward brake disc <NUM> or the direction from brake disc <NUM> toward insert <NUM>, such that movement of insert <NUM> in the first radial direction R1 and/or second radial direction R2 is substantially limited. For example, rivet slot <NUM> may be configured such that second dimension D2 is slightly larger than the cross-sectional dimension of rivet shank <NUM> (e.g., by about <NUM>%, <NUM>,%, <NUM>%, or another percentage of the cross-sectional dimension of rivet shank <NUM>) while remaining less than first dimension D1. In examples, first dimension D1 is a dimension measured in the first tangential direction T1 and/or the second tangential direction T2. Second dimension D2 may be a dimension measured in the direction substantially perpendicular to first dimension D1.

Rivet slot <NUM> and/or rivet <NUM> may be configured to allow for motion of insert <NUM> relative to brake disc <NUM>, rivet <NUM>, and/or washer <NUM> in the first tangential direction T1 and the second tangential direction T2. For example, rivet slot <NUM> and/or rivet <NUM> may be configured to allow for movement of insert <NUM> relative to brake disc <NUM>, rivet <NUM>, and/or washer <NUM> in the first tangential direction T1 when insert <NUM> receives a force in the first tangential direction T1, such that back face <NUM> moves in a direction away from first torque face <NUM>. Rivet slot <NUM> and/or rivet <NUM> may be configured to allow for movement of insert <NUM> relative to brake disc <NUM>, rivet <NUM>, and/or washer <NUM> in the second tangential direction T2 when insert <NUM> receives a force in the second tangential direction T2, such that back face <NUM> moves in a direction toward torque face <NUM>. Insert <NUM> may be configured to receive the force in the first tangential direction T1 and/or the second tangential direction T2 from a rotor drive key or a spline extending through disc slot <NUM>, as a result of an acceleration or deceleration of insert <NUM> (e.g., imparted due to vibrations of brake disc <NUM>, acceleration or deceleration of a vehicle carrying brake disc <NUM>, a gravity vector acting on insert <NUM>, or another event causing the acceleration or deceleration), or from another source. In examples, insert <NUM> is configured to move relative to brake disc <NUM>, rivet <NUM>, and washer <NUM> when insert <NUM> receives the force in the first tangential direction T1 and/or the second tangential direction T2.

In examples, rivet slot <NUM> is configured to allow insert <NUM> to substantially pivot around rivet shank <NUM> to at least some degree when torque is imparted by brake disc <NUM> (e.g., disc slot <NUM>) to a rotor drive key or a spline extending through disc slot <NUM>. Pivoting of insert <NUM> around rivet shank <NUM> may allow insert <NUM> (e.g., back face <NUM>) to seat more firmly and conform more effectively against brake disc <NUM> (e.g., first torque face <NUM>) when the torque is imparted. This may allow the insert <NUM> to distribute forces (e.g., reaction forces imparted to brake disc <NUM> from the rotor drive key or spline) more effectively over a torque face (e.g., first torque face <NUM>) of brake disc <NUM>, reducing stresses generated on brake disc <NUM> during a braking operation.

In examples, insert <NUM> defines a gap G (<FIG> and <FIG>) configured to receive a portion of disc <NUM> when insert <NUM> is positioned in disc slot <NUM>. Insert <NUM> may be configured such that gap G receives brake disc <NUM> when insert ear <NUM> covers first disc surface <NUM> and/or second insert ear <NUM> covers second disc surface <NUM>. Insert <NUM> may be configured such that gap G receives brake disc <NUM> when back face <NUM> covers first torque face <NUM>. In examples, insert <NUM> defines gap G over a displacement DG substantially separating insert ear <NUM> and second insert ear <NUM>. In examples, displacement DG is substantially parallel to the axial direction of brake disc <NUM> (e.g., parallel or nearly parallel to the extent permitted by manufacturing tolerances). In some examples, insert <NUM> defines displacement DG such that insert ear <NUM> slidably engages disc <NUM> (e.g., first disc surface <NUM>) and/or second insert ear <NUM> slidably engages disc <NUM> (e.g., second disc surface <NUM>) when insert <NUM> receives disc <NUM> within gap G.

Insert <NUM> may define displacement DG with respect to a radial direction of brake disc <NUM> in a manner configured to, for example, provide axial, radial, and/or tangential support to insert <NUM> when insert <NUM> is positioned within disc slot <NUM>. In some examples, displacement DG remains substantially constant (e.g., constant or nearly constant to the extent permitted by manufacturing tolerances) as insert ear <NUM> and second insert ear <NUM> extend in a radial direction of brake disc <NUM> (e.g., in the first radial direction R1 and/or second radial direction R2). In some examples, displacement DG varies with respect to the radial direction of brake disc <NUM>. For example, the displacement DG may increase in the first radial direction R1, such that insert ear <NUM> and second insert ear <NUM> generally slant away from each other as insert ear <NUM> and second insert ear <NUM> extend in the first radial direction R1. The displacement DG may decrease in the first radial direction R1, such that insert ear <NUM> and second insert ear <NUM> generally slant toward each other as insert ear <NUM> and second insert ear <NUM> extend in the first radial direction R1. Insert <NUM> may be configured to define DG with respect to the first radial direction R1 in any manner such that, for example, insert ear <NUM> engages first disc surface <NUM> when insert <NUM> experiences a force acting substantially in the first axial direction A1 and/or second insert ear <NUM> engages second disc surface <NUM> when insert <NUM> experiences a force acting substantially in the second axial direction A2. In some examples, insert <NUM> defines a displacement configured to vary in a tangential direction of brake disc <NUM>. For example, insert <NUM> may be configured to define the displacement such that the displacement increases in the second tangential direction T2, such that, for example, insert ear <NUM> and second insert ear <NUM> generally slant away from each other as insert ear <NUM> and second insert ear <NUM> extend (e.g., away from body <NUM>) in the second tangential direction T2. Insert <NUM> may be configured to define the displacement such that the displacement increases in the first tangential direction T1, such that, for example, insert ear <NUM> and second insert ear <NUM> generally slant towards each other as insert ear <NUM> and second insert ear <NUM> extend (e.g., away from body <NUM>) in the second tangential direction T2.

In some examples, for example as illustrated in <FIG>. , second insert ear <NUM> defines a second rivet slot <NUM> configured to allow passage of a rivet (e.g., rivet <NUM> or another rivet) through second insert ear <NUM> to assist in securing insert <NUM> to brake disc <NUM>. Insert assembly <NUM> may include a second washer <NUM> configured to position between a rivet head <NUM> and second insert ear <NUM> when the rivet passes through second rivet slot <NUM> and into brake disc <NUM>. In examples, second washer <NUM> defines a second washer hole <NUM> configured to allow passage of the rivet through second washer hole <NUM>. Second washer hole <NUM> may be configured (e.g., dimensioned) to prevent passage of second rivet head <NUM> through second washer hole <NUM> when the rivet extends through second washer hole <NUM>, extends through second rivet slot <NUM>, and extends into brake disc <NUM>. Second washer <NUM> may be configured to position between rivet head <NUM> and second rivet slot <NUM> when the rivet passes through second washer hole <NUM>, second rivet slot <NUM>, and into brake disc <NUM>.

Rivet head <NUM> may be configured to provide axial support to washer <NUM> and/or insert <NUM> when rivet <NUM> extends through washer hole <NUM> and rivet slot <NUM> and insert <NUM> is positioned within disc slot <NUM>. For example, rivet head <NUM> may be configured to engage (or remain engaged with) washer <NUM> when washer <NUM> experiences a force acting in a direction from brake disc <NUM> toward washer <NUM> (e.g., a force in the second axial direction A2). Rivet <NUM> may be configured such that rivet head <NUM> imparts a reaction force on washer <NUM> that opposes the force acting in the direction from brake disc <NUM> toward washer <NUM>, such that movement of washer <NUM> in the second axial direction A2 is substantially limited and/or prevented. Washer <NUM> may be configured to transmit at least some portion of the reaction force exerted by rivet head <NUM> to insert ear <NUM>, such that movement of insert ear <NUM> in the second axial direction A2 is substantially limited and/or prevented.

In examples, rivet <NUM> (e.g., rivet shank <NUM>) is configured to extend through both rivet slot <NUM> and second rivet slot <NUM> at the same time. For example, rivet <NUM> may be configured to extend (e.g., via rivet hole <NUM>) between disc first side <NUM> (e.g., first disc surface <NUM>) and disc second side <NUM> (e.g., second disc surface <NUM>). In examples, rivet head <NUM> is a second rivet head at a second end portion of rivet shank <NUM> (e.g., a second end portion opposite the first end portion of rivet shank <NUM>). Hence, rivet shank <NUM> may be configured to pass through washer hole <NUM>, rivet slot <NUM>, brake disc <NUM>, second rivet slot <NUM>, and second washer hole <NUM>. Rivet <NUM> may be configured such that washer <NUM> is between rivet head <NUM> and first insert ear <NUM> and second washer <NUM> is between rivet head <NUM> and second insert ear <NUM> when rivet shank <NUM> extends (e.g., via rivet hole <NUM>) between disc first side <NUM> (e.g., first disc surface <NUM>) and disc second side <NUM> (e.g., first disc surface <NUM>). Second insert ear <NUM>, second rivet slot <NUM>, second washer <NUM>, second washer hole <NUM>, the rivet extending through second washer hole <NUM> (e.g., rivet <NUM>), rivet head <NUM>, rivet hole <NUM>, and/or second disc surface <NUM> may be configured individually and relative to each other in the same or similar manner as that described for the individual and relative configurations described for first insert ear <NUM>, rivet slot <NUM>, washer <NUM>, washer hole <NUM>, rivet <NUM>, rivet head <NUM> and/or first disc surface <NUM>.

For example, second rivet slot <NUM> may be configured to allow motion of insert <NUM> (e.g., relative to brake disc <NUM>, rivet <NUM>, and/or second washer <NUM>) in a tangential direction of brake disc <NUM> (e.g., in the first tangential direction T1 and/or second tangential direction T2) when insert <NUM> (e.g., drive face <NUM>) engages a rotor drive key or spline extending through disc slot <NUM> and insert <NUM> is connected to brake disc <NUM> via rivet <NUM>. The tangential motion allowed by second rivet slot <NUM> may cause insert <NUM> to engage brake disc <NUM> (e.g., cause back face <NUM> to engage first torque face <NUM>). Second rivet slot <NUM> may be configured to allow the tangential motion of insert <NUM> when rivet slot <NUM> allows the tangential motion of insert <NUM>. For example, when a braking operation causes brake disc <NUM> to cause motion of insert <NUM> relative to the rotor drive key or spline extending through disc slot <NUM>, insert <NUM> may be configured such that rivet slot <NUM> and second rivet slot <NUM> allow the tangential motion of insert <NUM> relative to brake disc <NUM>, rivet <NUM>, washer <NUM>, and/or second washer <NUM>. Insert <NUM> may be configured such that insert ear <NUM> slides over first disc surface <NUM> and/or second insert ear <NUM> slides over second disc surface <NUM> when rivet slot <NUM> and second rivet slot <NUM> allow the tangential motion of insert <NUM> relative to brake disc <NUM>, rivet <NUM>, washer <NUM> and/or second washer <NUM> ("washers <NUM>, <NUM>"). In examples, second rivet slot <NUM> is elongated and includes a dimension similar to (e.g., identical or nearly identical to the extent permitted by manufacturing tolerances) dimension D1 of rivet slot <NUM> and a dimension similar to dimension D2 of rivet slot <NUM>.

In examples, rivet slot <NUM> and/or second rivet slot <NUM> ("rivets slots <NUM>, <NUM>") are configured to allow for tangential motion of insert <NUM> relative to brake disc <NUM>, rivet <NUM>, and/or washers <NUM>, <NUM> in a manner reducing and/or substantially limiting loading (e.g., shear loading) of rivet shank <NUM>. For example, insert assembly <NUM> (e.g., body section <NUM> and/or rivet slots <NUM>, <NUM>) may be configured such that, when insert assembly <NUM> is positioned within disc slot <NUM> and insert <NUM> moves tangentially with respect to brake disc <NUM>, back face <NUM> engages brake disc <NUM> such that slot boundary <NUM> of rivet slot <NUM> is substantially prevented from imparting a force (e.g., a shear force) against rivet shank <NUM> as brake disc <NUM> imparts torque to a rotor drive key or spline via insert <NUM>. This may reduce and/or substantially eliminate shear forces imparted to the rivet <NUM>, such that the rivet <NUM> (e.g., rivet shank <NUM>) remains relatively unloaded by the impartation of torque from brake disc <NUM> to the rotor drive key or spline. For example, rivet shank <NUM> may remain relatively unloaded compared to a rivet shank extending through a nonelongated, circular rivet slot.

For example, <FIG> are cross-sectional top views of a portion of insert assembly <NUM> positioned within disc slot <NUM>, with the cross-section taken over the cutting plane illustrated as B-B' in <FIG>. In <FIG>, the second radial direction R2 is perpendicular to and proceeds out of the page, the first radial direction R1 is perpendicular to and proceeds into the page, and first axial direction A1, second axial direction A2, first tangential direction T1, and second tangential direction T2 are parallel to the page. <FIG> depicts the portion of insert assembly <NUM> with an absence of forces acting on insert <NUM> (e.g., body section <NUM>) in the first tangential direction T1 or the second tangential direction T2. <FIG> depicts the portion of insert assembly <NUM> with a force F1 acting on insert <NUM> (e.g., body section <NUM>) in the second tangential direction T2, such that insert <NUM> has moved relative to brake disc <NUM>, rivet <NUM>, and/or washers <NUM>, <NUM> as compared to the position of insert <NUM> depicted in <FIG>.

Referring to <FIG>, with insert <NUM> secured to brake disc <NUM> by rivet <NUM>, insert <NUM> is configured to translate a first distance DS1 relative to brake disc <NUM> to cause back face <NUM> of insert <NUM> to engage first torque face <NUM> of brake disc <NUM>. Insert <NUM> is configured to translate the first distance DS1 when force F1 acts on body section <NUM> of insert <NUM> (e.g., drive face <NUM>) in the second tangential direction T2. Force F1 may be a force imparted to drive face <NUM> from a rotor drive key or a spline extending through disc slot <NUM>. Force F1 may result from, for example, contact between the rotor drive key or the spline and drive face <NUM> as brake disc <NUM> experiences a torque (e.g., a torque caused by rotation of wheel <NUM> (<FIG>), and/or a shearing force imparted to disc first side <NUM> and/or disc second side <NUM> from a rotor disc or stator disc within disc stack <NUM>). For example, force F1 may be a force from a rotor drive key as the rotor drive key imparts a torque around disc axis A (<FIG>) from wheel <NUM> to brake disc <NUM>. As another example, force F1 may be a force imparted from a spline (e.g., a reaction force) as brake disc <NUM> transfers a torque around disc axis A to the spline.

In examples, rivets slots <NUM>, <NUM> are configured to substantially limit and/or prevent slot boundary <NUM> from imparting a force (e.g., a force in the second tangential direction T2) from body section <NUM> to rivet shank <NUM> when the force F1 is imparted to insert <NUM>. In examples, rivet slots <NUM>, <NUM> are configured such that rivet shank <NUM> is separated from a portion of slot boundary <NUM> by a second distance DS2 greater than first distance DS1 when insert <NUM> is positioned within disc slot <NUM>. In examples, second distance DS2 is a portion (e.g., less than <NUM>%) of first dimension D1 (<FIG>). Insert <NUM> may be configured such that engagement (e.g., contact) of back face <NUM> with first torque face <NUM> ceases the movement of insert <NUM> relative to brake disc <NUM>, such that rivet shank <NUM> is separated from the portion of slot boundary by a third distance DS3 (<FIG>). The separation of rivet shank <NUM> from the portion of slot boundary <NUM> by the distance DS3 may substantially limit and/or prevent slot boundary <NUM> from imparting a force (e.g., a force in the second tangential direction T2) from body section <NUM> to rivet shank <NUM> when the force F1 is imparted to insert <NUM>.

In examples, distance DS1, distance DS2 , and/or distance DS3 are distances extending in a direction substantially parallel (e.g., parallel or nearly parallel to the extent permitted by manufacturing tolerances) to the first tangential direction T1 and/or the second tangential direction T2 of brake disc <NUM>. In examples, distance DS3 is a portion of and less than distance DS2. In some examples, insert <NUM> is configured such that when second back face <NUM> (<FIG>) engages (e.g., contacts) second torque face <NUM>, back face <NUM> is separated from first torque face <NUM> by a distance greater than or equal to distance DS1, and/or rivet shank <NUM> is separated from slot boundary <NUM> in the first tangential direction T1 or the second tangential direction T2 by a distance greater than or equal to distance DS2.

As discussed, washer <NUM> is configured to position between rivet head <NUM> and insert ear <NUM> when insert <NUM> is positioned in disc slot <NUM> and rivet <NUM> extends through rivet slot <NUM>. For example, <FIG> is a cross-sectional side view of a portion of insert assembly <NUM> including washer <NUM> and a portion of insert ear <NUM>, with the cross-section taken over the cutting plane illustrated as C-C' in <FIG>. In <FIG>, second tangential direction T2 is perpendicular to and proceeds out of the page, first tangential direction T1 (not shown) is perpendicular to and proceeds into the page, and first axial direction A1, second axial direction A2, first tangential direction T1, and second tangential direction T2 parallel to the page. Rivet <NUM> is depicted as transparent and illustrated with dashed lines, and extends through washer hole <NUM>, rivet slot <NUM>, and into rivet hole <NUM> to secure insert <NUM> to brake disc <NUM>.

In examples, insert ear <NUM> includes an insert ear body <NUM> defining a first ear surface <NUM> configured to face first disc surface <NUM> of brake disc <NUM> when rivet <NUM> secures insert <NUM> to brake disc <NUM>. Insert ear body <NUM> defines a second ear surface <NUM> configured to face washer <NUM> when washer <NUM> is positioned between rivet head <NUM> and insert ear <NUM>. In examples, first ear surface <NUM> is configured to engage (e.g., slidably engage) first disc surface <NUM> when rivet <NUM> secures insert <NUM> to brake disc <NUM>. Second ear surface <NUM> may be configured to engage (e.g., slidably engage) washer <NUM> when rivet <NUM> secures insert <NUM> to brake disc <NUM>. For example, first ear surface <NUM> may be configured to slide over (e.g., slide against) first disc surface <NUM> and/or second ear surface <NUM> may be configured to slide over (e.g., slide against) washer <NUM> when insert <NUM> moves in a tangential direction (e.g., in the first tangential direction T1 or second tangential direction T2) relative to brake disc <NUM>, rivet <NUM>, and/or washer <NUM>.

Washer <NUM> may include a washer body <NUM> defining a first washer surface <NUM> configured to face insert <NUM> (e.g., second ear surface <NUM>) when rivet <NUM> secures insert <NUM> to brake disc <NUM>. Washer body <NUM> defines a second washer surface <NUM> configured to face in a direction away from insert <NUM> (e.g., away from second ear surface <NUM>) when washer <NUM> is positioned between rivet head <NUM> and insert ear <NUM>. In examples, first washer surface <NUM> is configured to engage (e.g., slidably engage) insert ear <NUM> (e.g., second ear surface <NUM>) when rivet <NUM> secures insert <NUM> to brake disc <NUM>. Washer body <NUM> may be configured to remain substantially stationary with respect to rivet <NUM> when rivet <NUM> secures insert <NUM> to brake disc <NUM> (e.g., when rivet <NUM> extends through washer hole <NUM>, rivet slot <NUM>, and into rivet hole <NUM>). For example, first washer surface <NUM> may be configured to slide relative to (e.g., slide against) second ear surface <NUM> when insert <NUM> moves in a tangential direction (e.g., in the first tangential direction T1 or second tangential direction T2) relative to brake disc <NUM>, rivet <NUM>, and/or washer <NUM>. Washer body <NUM> may be configured to remain substantially stationary with respect to rivet <NUM>, and/or brake disc <NUM> when insert <NUM> moves in the tangential direction relative to brake disc <NUM>, rivet <NUM>, and/or washer <NUM>.

In examples, at least some portion of insert ear body <NUM> separates first ear surface <NUM> and second ear surface <NUM>. In examples, first ear surface <NUM> and/or second ear surface <NUM> are substantially parallel (e.g., parallel or nearly parallel to the extent permitted by manufacturing tolerances) to a plane defined by an axial direction of brake disc <NUM> (e.g., first axial direction A1 and/or second axial direction A2) and a radial direction of brake disc <NUM> (e.g., first radial direction R1 and/or second radial direction R2) when insert <NUM> is positioned with disc slot <NUM>.

In examples, at least some portion of washer body <NUM> separates first washer surface <NUM> and second washer surface <NUM>. In examples, first washer surface <NUM> and/or second washer surface <NUM> are substantially parallel (e.g., parallel or nearly parallel to the extent permitted by manufacturing tolerances) to a plane defined by an axial direction of brake disc <NUM> (e.g., first axial direction A1 and/or second axial direction A2) and a radial direction of brake disc <NUM> (e.g., first radial direction R1 and/or second radial direction R2) when insert <NUM> is positioned with disc slot <NUM>. Hence, insert assembly <NUM> may be configured such that, during tangential motion of insert <NUM> relative to brake disc <NUM>, rivet <NUM>, and/or washer <NUM>, insert <NUM> may slide in a tangential direction (e.g., in the first tangential direction T1 or second tangential direction T2) between washer <NUM> and brake disc <NUM>.

In some examples, rivet head <NUM> is an orbitally riveted head fabricated using an orbital riveting tool (e.g., a peen tool). Washer <NUM> may be configured to allow for the orbital riveting (and/or another cold forming process) of rivet head <NUM> in a manner which limits and/or substantially prevents deformation of rivet head <NUM> into rivet slot <NUM> during the orbital riveting process. For example, insert <NUM> may be positioned within disc slot <NUM> and rivet shank <NUM> extended through washer hole <NUM>, rivet slot <NUM>, and into the brake disc <NUM> (e.g., via rivet hole <NUM>), prior to fabricating rivet head <NUM>. Rivet head <NUM> may be fabricated by deforming a portion of rivet <NUM> (e.g., an end portion <NUM> at an end of rivet shank <NUM>) to cause end portion <NUM> to substantially collapse against washer <NUM>. Washer <NUM> may be configured to substantially separate the forming or formed rivet head <NUM> from rivet slot <NUM> to, for example, limit and/or substantially prevent rivet <NUM> from deforming into rivet slot <NUM>.

Washer <NUM> may include a boundary <NUM> ("washer hole boundary <NUM>") which defines washer hole <NUM>. Washer hole boundary <NUM> may be configured to radially support a portion of rivet shank <NUM> (e.g., a portion immediately adjacent the forming or formed rivet head <NUM>) to, for example, limit and/or substantially preventing expansion of rivet shank <NUM> within rivet slot <NUM> during the orbital riveting process. Hence, washer <NUM> may be configured to reduce and/or limit physical interference between rivet slot <NUM> and rivet head <NUM> and/or rivet shank <NUM> that might otherwise limit and/or substantially prevent motion of the insert <NUM> relative to brake disc <NUM>, washer <NUM>, and/or rivet <NUM>. In examples, rivet <NUM> is a solid rivet and rivet shank <NUM> is substantially solid rivet shank (rather than, e.g., a hollow rivet, semi-tubular rivet), such that the rivet may be considered a solid rivet. For example, rivet <NUM> may be a solid rivet defining a solid, unified body over an outer cross-sectional dimension (e.g., an outer diameter) of rivet shank <NUM>.

Washer <NUM> may define a countersink <NUM>, for example, reduce a length of rivet shank <NUM> and/or limit a protrusion of rivet head <NUM> beyond washer <NUM>. For example, washer <NUM> may define countersink <NUM> to reduce and/or substantially eliminate a protrusion of rivet head <NUM> beyond second washer surface <NUM> in the second axial direction A2. In examples, countersink <NUM> is a portion of washer hole <NUM>. Countersink <NUM> may be present to reduce potential interference between brake disc <NUM> and other discs within a disc stack (e.g., one or more of rotor discs <NUM>, <NUM>, <NUM>, <NUM> and/or stator discs <NUM>, <NUM>, <NUM> within disc stack <NUM> (<FIG>)). In examples, countersink <NUM> is configured such rivet head <NUM> imparts a reaction force on washer <NUM> opposing a force on washer <NUM> acting in a direction from washer <NUM> toward rivet head <NUM> (e.g., a force in the second axial direction A2), such that movement of washer <NUM> in a direction from washer <NUM> toward rivet head <NUM> is substantially limited and/or prevented.

Countersink <NUM> may define an opening which opens to second washer surface <NUM>. In examples, countersink <NUM> defines a major dimension DM and a hole dimension DH. Major dimension DM may be greater than hole dimension DH. In examples, major dimension DM is a cross-sectional dimension (e.g., a diameter) of a countersink boundary <NUM> defined by washer <NUM> (e.g., defined by a closed boundary of second washer surface <NUM>). In examples, hole dimension DH is a cross-sectional dimension (e.g., a diameter) of a portion of washer hole <NUM> configured to surround rivet shank <NUM>. Countersink boundary <NUM> may define, for example, a curved shape such as a circle, oval, or other curved shape. In some examples, countersink boundary <NUM> defines a curvilinear shape comprising curved and linear segments. In other examples, countersink boundary <NUM> defines a polygon. In examples, countersink <NUM> is a tapered inset defining a countersink angle ("CS angle") which describes a taper as countersink <NUM> transitions from major dimension DM to minor dimension DH. In some examples, counter sink <NUM> is a counterbore defining an inset (e.g., a substantially cylindrical inset) extending from countersink boundary into washer body <NUM>. The inset may define one or more sides extending from countersink boundary <NUM> into washer body in a direction substantially parallel (e.g., parallel or nearly parallel to the extent permitted by manufacturing tolerances) to first axial direction A1.

In examples, washer <NUM> is configured to substantially overhang at least some portion of rivet slot <NUM> when rivet <NUM> extends through washer hole <NUM> and rivet slot <NUM>. For example, as depicted in <FIG>, washer <NUM> may be configured to extend across (e.g., bridge and/or span) rivet slot <NUM> from a first portion of slot boundary <NUM> to a second portion of slot boundary <NUM>, where the first portion of slot boundary <NUM> is displaced from the second portion of slot boundary <NUM> by second dimension D2. In examples, washer <NUM> is configured (e.g., dimensioned) such that, for example, washer <NUM> provides sufficient support to rivet <NUM> during an orbital riveting process or other type of riveting process as washer <NUM> extends across rivet slot <NUM>. For example, washer <NUM> may define a thickness T such that washer <NUM> may provide sufficient support to cause rivet head <NUM> to collapse against washer <NUM> (e.g., second washer surface <NUM> and/or a surface defining countersink <NUM>) as end portion <NUM> of rivet <NUM> is deformed (e.g., by an orbital riveting tool) to define rivet head <NUM>.

Thickness T may be a dimension of washer <NUM> substantially parallel (e.g., parallel or nearly parallel to the extent permitted by manufacturing tolerances) to first axial direction A1 and/or second axial direction A2 when rivet <NUM> extends through washer hole <NUM> and into brake disc <NUM> (e.g., via rivet hole <NUM>). In examples, washer <NUM> defines a outer dimension DO (e.g., an outer diameter) substantially parallel (e.g., parallel or nearly parallel to the extent permitted by manufacturing tolerances) to first radial direction R1 and/or second radial direction R2 when rivet <NUM> extends through washer hole <NUM> and into brake disc <NUM> (e.g., via rivet hole <NUM>). In some examples, thickness T defines a dimension of at least <NUM>% of a length defined by outer dimension DO, such as a length greater than <NUM>%, <NUM>%, or <NUM>% of the length defined by outer dimension DO. In some examples, thickness T defines a dimension of at least <NUM>% of a length defined by major dimension DM and/or hole diameter DH, such as a length greater than <NUM>%, <NUM>%, or <NUM>% of the length defined by major dimension DM and/or hole diameter DH.

In examples, insert assembly <NUM> is configured to cover first torque face <NUM> and second torque face <NUM> when insert <NUM> is positioned within disc slot <NUM>. Insert assembly <NUM> may be configured to allow movement of insert <NUM> toward first torque face <NUM> (e.g., in the second tangential direction T2) when insert <NUM> receives a force in the second tangential direction T2 and configured to allow movement of insert <NUM> toward second torque face <NUM> (e.g., in the first tangential direction T1) when insert <NUM> receives a force in the first tangential direction T1. In examples, when insert <NUM> is positioned in disc slot <NUM>, insert <NUM> is configured to engage first torque face <NUM> when insert <NUM> receives the force in the second tangential direction T2 and configured to engage second torque face <NUM> when insert <NUM> receives the force in the first tangential direction T1.

For example, <FIG> illustrates the cross-sectional top view of <FIG> including body section <NUM> of insert <NUM>, first torque face <NUM>, rivet <NUM>, washer <NUM>, and second torque face <NUM>. In examples, insert assembly <NUM> (e.g., insert <NUM>) includes a second body section <NUM> configured to cover second torque face <NUM> when insert <NUM> is positioned within disc slot <NUM>. Second body section <NUM> defines a drive face <NUM> ("second drive face <NUM>") and a back face <NUM> ("second back face <NUM>") opposite second drive face <NUM>. In examples, at least some portion of second body section <NUM> separates second drive face <NUM> and second back face <NUM>. Second drive face <NUM> may be configured to engage a rotor drive key or a spline when insert <NUM> is positioned in disc slot <NUM> and brake disc <NUM> imparts a torque to the rotor drive key or spline (e.g., a torque imparting a force to the rotor drive key or spline in the second tangential direction T2). Second back face <NUM> may be configured to engage second torque face <NUM> when brake disc <NUM> imparts the torque to the rotor drive key or spline, such that the brake disc <NUM> imparts the torque to the rotor drive key or spline via insert <NUM>.

Insert assembly <NUM> (e.g., insert <NUM>) may be configured such that at least body section <NUM> and second body section <NUM> act as a substantially rigid body, such that, for example, a force causing movement of body section <NUM> relative to brake disc <NUM>, rivet <NUM>, and/or washer <NUM> further causes movement of second body section <NUM> relative to brake disc <NUM>, rivet <NUM>, and/or washer <NUM>. In examples, insert assembly <NUM> is configured such that a force (e.g., a minimum force) imparted on insert <NUM> in the first tangential direction T1 may cause movement of body section <NUM> and second body section <NUM> in the first tangential direction T1. Insert assembly <NUM> may be configured such that a force (e.g., a minimum force) imparted on insert <NUM> in the second tangential direction T2 may cause movement of body section <NUM> and second body section <NUM> in the second tangential direction T2. In examples, insert assembly <NUM> is configured such that a rotor drive key or a spline extends between body section <NUM> and second body section <NUM> when insert <NUM> is positioned within disc slot <NUM> and the rotor drive key or spline extends through disc slot <NUM>.

In examples, insert <NUM> includes a bridge member <NUM> configured transfer a force from body section <NUM> to second body section <NUM>, and vice-versa. Bridge member <NUM> extends between body section <NUM> and second body section <NUM>. In examples, insert <NUM> is configured such that bridge member <NUM> acts as a substantially rigid body with body section <NUM> and/or second body section <NUM>, such that, for example, a force causing movement of body section <NUM> and/or second body section <NUM> relative to brake disc <NUM>, rivet <NUM>, and/or washer <NUM> causes movement of bridge member <NUM> relative to brake disc <NUM>, rivet <NUM>, and/or washer <NUM>. For example, insert assembly <NUM> may be configured such that a force imparted on body section <NUM> and/or second body section <NUM> in the first tangential direction T1 may cause movement of bridge member <NUM> in the first tangential direction T1. Insert assembly <NUM> may be configured such that a force imparted on body section <NUM> and/or second body section <NUM> in the second tangential direction T2 may cause movement of bridge member <NUM> in the second tangential direction T2.

In examples, insert assembly <NUM> is configured such that, when insert <NUM> is positioned within disc slot <NUM> and the rotor drive key or a spline extends through disc slot <NUM>, bridge member <NUM> is positioned between disc <NUM> and the rotor drive key or the spline. In examples, insert assembly <NUM> is configured such that, when insert <NUM> is positioned within disc slot <NUM> and the rotor drive key or the spline extends through disc slot <NUM>, body section <NUM>, bridge member <NUM>, and second body section <NUM> substantially surround some portion of the rotor drive key or spline. In some examples, bridge member <NUM>, body section <NUM>, and second body section <NUM> define a substantially unified body (e.g., a unified body formed by casting, machining, or another process). In some examples, bridge member <NUM> may be attached to body section <NUM> and/or second body section <NUM> (e.g., attached by welding, soldering, a fastener, an adhesive, physical mating of bridge member <NUM> and body section <NUM> and/or second body section <NUM>, or another attachment method).

Insert assembly <NUM> may include a third insert ear <NUM>, a fourth insert ear <NUM>, a third rivet slot <NUM>, a fourth rivet slot <NUM>, a second rivet <NUM> including a second rivet shank <NUM>, rivet head <NUM>, and/or rivet head <NUM>, a third washer <NUM>, and/or a fourth washer <NUM>. Brake disc <NUM> may further define a third disc surface <NUM>, a fourth disc surface <NUM>, and/or a second rivet hole <NUM>. Third insert ear <NUM>, fourth insert ear <NUM>, third rivet slot <NUM>, fourth rivet slot <NUM>, second rivet <NUM>, second rivet shank <NUM>, rivet head <NUM>, rivet head <NUM>, third washer <NUM>, fourth washer <NUM>, third disc surface <NUM>, fourth disc surface <NUM>, and/or second rivet hole <NUM> may be configured individually and relative to each other in the same or similar manner as that described for the individual and relative configurations described for insert ear <NUM>, second insert ear <NUM>, rivet slot <NUM>, second rivet slot <NUM>, rivet <NUM>, rivet shank <NUM>, rivet head <NUM>, rivet head <NUM>, washer <NUM>, second washer <NUM>, first disc surface <NUM>, second disc surface <NUM>, and/or rivet hole <NUM> respectively.

For example, third insert ear <NUM> of insert <NUM> may be configured to cover third disc surface <NUM> (<FIG>) of brake disc <NUM> when insert <NUM> is positioned within disc slot <NUM>. Third disc surface may be a portion of disc first side <NUM>. In some examples, fourth insert ear <NUM> is configured to cover a fourth disc surface <NUM> (<FIG>) of brake disc <NUM> when insert <NUM> is positioned within disc slot <NUM>. In examples, third insert ear <NUM> and/or fourth insert ear <NUM> extend from second body section <NUM> in a substantially tangential direction of brake disc <NUM> (e.g., in the first tangential direction T1) when insert <NUM> is positioned within disc slot <NUM>. In examples, third disc surface <NUM> and/or fourth disc surface <NUM> are adjacent disc slot <NUM> and/or second torque face <NUM>.

In examples, third insert ear <NUM> and/or fourth insert ear <NUM> are configured to provide axial support to insert <NUM> when insert <NUM> is positioned within disc slot <NUM>. For example, third insert ear <NUM> may be configured to engage (or remain engaged with) third disc surface <NUM> when insert <NUM> experiences a force acting in the first axial direction A1. Fourth insert ear <NUM> may be configured to engage (or remain engaged with) fourth disc surface <NUM> when insert <NUM> experiences a force acting in the second axial direction A2. Insert <NUM> may be configured such that third disc surface <NUM> imparts a reaction force on insert <NUM> (e.g., third insert ear <NUM>) opposing the force acting in the first axial direction A1 and/or fourth disc surface <NUM> imparts a reaction force on insert <NUM> (e.g., fourth insert ear <NUM>) opposing the force acting in the second axial direction A2, such that movement of insert <NUM> in the first axial direction A1 and/or the second axial direction A2 is substantially limited and/or prevented. In some examples, third insert ear <NUM> is configured to cover third disc surface <NUM> and/or fourth insert ear <NUM> is configured to cover fourth disc surface <NUM> when insert <NUM> (e.g., second back face <NUM>) covers second torque face <NUM>.

Insert <NUM> may include third rivet slot <NUM> (e.g., defined by third insert ear <NUM>) and/or a fourth rivet slot <NUM> (e.g., defined by fourth insert ear <NUM>) configured to allow passage of second rivet <NUM> (e.g., second rivet shank <NUM>) through insert <NUM> to secure insert <NUM> to brake disc <NUM>. Third washer <NUM> may be configured to position between rivet head <NUM> of second rivet <NUM> and insert <NUM> (e.g., third insert ear <NUM>) when second rivet <NUM> secures insert <NUM> to brake disc <NUM>. Fourth washer <NUM> may be configured to position between rivet head <NUM> of second rivet <NUM> and insert <NUM> (e.g., fourth insert ear <NUM>) when second rivet <NUM> secures insert <NUM> to brake disc <NUM>. For example, third washer <NUM> may define a washer hole configured to allow passage of second rivet shank <NUM> through third washer <NUM>. Fourth washer <NUM> may define a washer hole configured to allow passage of second rivet shank <NUM> through fourth washer <NUM>.

Second rivet shank <NUM> is configured to insert into brake disc <NUM> via second rivet hole <NUM> in brake disc <NUM>. For example, second rivet shank <NUM> may be configured to extend (e.g., via second rivet hole <NUM>) between disc first side <NUM> (e.g., third disc surface <NUM>) and disc second side <NUM> (e.g., fourth disc surface <NUM>). In the example shown in <FIG>, second rivet <NUM> includes rivet head <NUM> at an opposite end of second rivet shank <NUM> from rivet head <NUM>. Hence, second rivet shank <NUM> may be configured to pass through third washer <NUM>, third rivet slot <NUM>, brake disc <NUM>, fourth rivet slot <NUM>, and fourth washer <NUM>. Second rivet <NUM> may be configured such that third washer <NUM> is between rivet head <NUM> and third insert ear <NUM> and fourth washer <NUM> is between rivet head <NUM> and fourth insert ear <NUM> when second rivet shank <NUM> extends (e.g., via second rivet hole <NUM>) between disc first side <NUM> (e.g., third disc surface <NUM>) and disc second side <NUM> (e.g., fourth disc surface <NUM>).

Third rivet slot <NUM> and/or fourth rivet slot <NUM> may be configured to allow motion of insert <NUM> (e.g., relative to brake disc <NUM>, rivet <NUM>, second rivet <NUM>, washer <NUM>, second washer <NUM>, third washer <NUM>, and/or fourth washer <NUM>) in a tangential direction of brake disc <NUM> (e.g., in the first tangential direction T1 and/or second tangential direction T2) when insert <NUM> (e.g., drive face <NUM>) engages a rotor drive key or spline extending through disc slot <NUM> and insert <NUM> is connected to brake disc <NUM> via second rivet <NUM>. The tangential motion allowed by third rivet slot <NUM> and/or fourth rivet slot <NUM> may cause insert <NUM> to engage brake disc <NUM> (e.g., cause second back face <NUM> to engage second torque face <NUM>). For example, when a braking operation causes brake disc <NUM> to cause motion of insert <NUM> relative to the rotor drive key or spline extending through disc slot <NUM>, insert <NUM> may be configured such that rivet slot <NUM>, second rivet slot <NUM>, third rivet slot <NUM>, and/or fourth rivet slot <NUM> allow the tangential motion of insert <NUM> relative to brake disc <NUM>, rivet <NUM>, second rivet <NUM>, washer <NUM>, second washer <NUM>, third washer <NUM>, and/or fourth washer <NUM>. In examples, each of third rivet slot <NUM> and/or fourth rivet slot <NUM> include a dimension similar to dimension D1 of rivet slot <NUM> and a dimension similar to dimension D2 of rivet slot <NUM>.

<FIG> illustrates a flow diagram of an example technique for positioning a drive insert on a disc slot of a brake disc. Although the technique is described with reference to insert assembly <NUM> and brake disc <NUM> of <FIG>, in other examples, the technique may be used with another insert assembly and brake disc.

The technique includes covering a first torque face <NUM> and/or a second torque face <NUM> of a brake disc <NUM> with an insert <NUM> to position insert <NUM> within a disc slot <NUM> of brake disc <NUM> (<NUM>). In examples, covering first torque face <NUM> and/or a second torque face <NUM> includes covering first torque face <NUM> using back face <NUM>. Insert ear <NUM> may cover first disc surface <NUM> and/or second insert ear <NUM> may cover second disc surface <NUM> when insert <NUM> covers first torque face <NUM> and/or a second torque face <NUM>. In examples, third insert ear <NUM> covers third disc surface <NUM> and/or fourth insert ear <NUM> covers fourth disc surface <NUM> when insert <NUM> covers first torque face <NUM> and/or a second torque face <NUM>. In examples, insert <NUM> receives a portion of brake disc <NUM> within a gap G defined by insert <NUM> when insert <NUM> covers first torque face <NUM> and/or a second torque face <NUM>.

The technique includes extending a rivet <NUM> (e.g., a rivet shank <NUM>) through a washer hole <NUM> of a washer <NUM>, through a rivet slot <NUM> defined by insert ear <NUM>, and into brake disc <NUM> to secure insert <NUM> to brake disc <NUM> (<NUM>). Rivet slot <NUM> is configured to enable tangential motion of insert <NUM> relative to brake disc <NUM>, rivet <NUM>, and/or washer <NUM> when rivet <NUM> secures insert <NUM> to brake disc <NUM>. Washer <NUM> may be positioned between a rivet head <NUM> of rivet <NUM> and insert ear <NUM> when rivet <NUM> secures insert <NUM> to brake disc <NUM>. In examples, a first ear surface <NUM> slidably engages first disc surface <NUM> and a second ear surface <NUM> slidably engages a first washer surface <NUM> when rivet <NUM> secures insert <NUM> to brake disc <NUM>.

In examples, rivet <NUM> extends through rivet hole <NUM> to secure insert <NUM> to brake disc <NUM>. Rivet <NUM> may also extend through a second rivet slot <NUM> of second insert ear <NUM> when rivet <NUM> extends through rivet hole <NUM>. In examples, rivet <NUM> extends through a second washer hole <NUM> of a second washer <NUM> when rivet <NUM> extends through second rivet slot <NUM>. Second rivet slot <NUM> is also configured to allow for tangential motion of insert <NUM> relative to brake disc <NUM>, rivet <NUM>, and/or washer <NUM> when rivet <NUM> extends through second rivet slot <NUM> and/or second washer hole <NUM>. Second washer <NUM> may be positioned between a rivet head <NUM> of rivet <NUM> and insert ear <NUM> when rivet <NUM> extends through second rivet slot <NUM> and second washer hole <NUM>. In examples, second insert ear <NUM> slidably engages a disc second side <NUM> and second washer <NUM> slidably engages second insert ear <NUM> when rivet <NUM> extends through second rivet slot <NUM> and second washer hole <NUM>.

In examples, the technique includes extending a second rivet <NUM> (e.g., a second rivet shank <NUM>) through a washer hole of a third washer <NUM>, through a third rivet slot <NUM> defined by third insert ear <NUM>, and into brake disc <NUM> to secure insert <NUM> to brake disc <NUM>. Second rivet <NUM> may extend through a second rivet hole <NUM> to secure insert <NUM> to brake disc <NUM>. Second rivet <NUM> may extend through a fourth rivet slot <NUM> defined by fourth insert ear <NUM> when second rivet <NUM> extends through second rivet hole <NUM>. In examples, second rivet <NUM> extends through a washer hole of a fourth washer <NUM> when second rivet <NUM> extends through fourth rivet slot <NUM>. Third washer <NUM> may be positioned between a rivet head <NUM> of second rivet <NUM> and third insert ear <NUM> and/or fourth washer <NUM> may be positioned between a rivet head <NUM> of second rivet <NUM> and fourth insert ear <NUM> when second rivet <NUM> secures insert <NUM> to brake disc <NUM>. In examples, third insert ear <NUM> slidably engages third disc surface <NUM> and third washer <NUM> slidably engages third insert ear <NUM> when second rivet <NUM> secures insert <NUM> to brake disc <NUM>. In examples, fourth insert ear <NUM> slidably engages fourth disc surface <NUM> and fourth washer <NUM> slidably engages fourth insert ear <NUM> when second rivet <NUM> secures insert <NUM> to brake disc <NUM>.

In some examples, the technique includes fabricating a rivet head <NUM>, <NUM> using an orbital riveting tool (e.g., a peen tool) as rivet shank <NUM> extends through washer hole <NUM>, <NUM>, rivet slot <NUM>, <NUM>, and into brake disc <NUM> (e.g., via rivet hole <NUM>). The technique may include fabricating rivet head <NUM>, <NUM> using an orbital riveting tool (e.g., a peen tool) as second rivet shank <NUM> extends through washer <NUM>, <NUM>, rivet slot <NUM>, <NUM>, and into brake disc <NUM> (e.g., via second rivet hole <NUM>). Fabricating rivet head <NUM>, <NUM>, <NUM>, <NUM> may include deforming a portion of rivet <NUM>, <NUM> (using, e.g., the orbital riveting tool) to cause an end portion (e.g., end portion <NUM>) of rivet <NUM>, <NUM> to substantially collapse against washer <NUM>, <NUM>, <NUM>, <NUM> (e.g., substantially collapse against second washer surface <NUM> and/or a surface defined by countersink <NUM>). Washer <NUM>, <NUM>, <NUM>, <NUM> may substantially separate the forming or formed rivet head <NUM>, <NUM>, <NUM>, <NUM> from rivet slot <NUM>, <NUM>, <NUM>, <NUM> during and/or following the fabrication of rivet head <NUM>, <NUM>, <NUM>, <NUM>. In examples, a washer hole boundary (e.g., washer hole boundary <NUM>) radially supports a portion of rivet shank <NUM>, <NUM> to, for example, limit and/or substantially prevent expansion of rivet shank <NUM>, <NUM> within rivet slot <NUM>, <NUM>, <NUM>, <NUM> during and/or following the fabrication of rivet head <NUM>, <NUM>, <NUM>, <NUM>.

In some examples, the technique includes positioning rivet head <NUM>, <NUM>, <NUM>, <NUM> in a countersink (e.g., countersink <NUM>) defined by washer <NUM>, <NUM>, <NUM>, <NUM>. In examples, positioning rivet head <NUM>, <NUM>, <NUM>, <NUM> in the countersink includes deforming a portion of rivet <NUM>, <NUM> (using, e.g., the orbital riveting tool) to cause a portion of rivet <NUM>, <NUM> (e.g., end portion <NUM>) to substantially collapse against a surface defining a boundary of the countersink. In examples, washer <NUM>, <NUM>, <NUM>, <NUM> substantially extends across (e.g., bridges and/or spans) at least some portion of rivet slot <NUM>, <NUM>, <NUM>, <NUM> as the portion of rivet <NUM>, <NUM> is deformed. Washer <NUM>, <NUM>, <NUM>, <NUM> may extend across rivet slot <NUM>, <NUM>, <NUM>, <NUM> from a first portion of a slot boundary (e.g., slot boundary <NUM>) to a second portion of the slot boundary displaced from the first portion of the slot boundary by second dimension D2.

Drive insert assembly <NUM> (e.g., insert <NUM>, washer <NUM>, <NUM>, <NUM>, <NUM>, and/or rivet <NUM>, <NUM>) described herein, as well as wheel <NUM> and brake system <NUM>, and the components thereof, may be made from any suitable material. For example, the material may be any material of suitable strength for the intended use of drive insert assembly <NUM>, wheel <NUM>, brake system <NUM>, and the components thereof. In some examples, the material includes a metal or a metal alloy. For example, the material may include a nickel alloy or steel alloy. As one example, the material may include stainless steel.

Drive insert assembly <NUM>, wheel <NUM>, brake system <NUM>, and the components thereof can be formed using any suitable technique. Drive insert assembly <NUM>, wheel <NUM>, brake system <NUM>, and the components thereof may be forged, casted, made from bar stock, additive manufactured (e.g., three-dimensionally (3D) printed), extruded, drawn, or be produced using other suitable methods. In some examples, drive insert assembly <NUM>, wheel <NUM>, brake system <NUM>, and the components thereof may be machined to define the configurations described herein. In other examples, drive insert assembly <NUM>, wheel <NUM>, brake system <NUM>, and the components thereof may be formed without having to be substantially machined.

Drive insert assembly <NUM>, wheel <NUM>, brake system <NUM>, and the components thereof, may be formed to have any shape. In some examples, two or more components of drive insert assembly <NUM>, wheel <NUM>, and brake system <NUM> are formed to be physically separate from each other and subsequently joined and/or attached to define drive insert assembly <NUM>, wheel <NUM>, and brake system <NUM>. In other examples, two or more components of drive insert assembly <NUM>, wheel <NUM>, and brake system <NUM> have a unitary body construction, e.g., are formed to be one piece.

In some examples, wheel <NUM> may be finish machined from a near-net-shaped aluminum forging and contain an axial assembly and/or wheel rim for assembly of brake system <NUM> onto wheel <NUM>. In other examples, wheel <NUM> may be manufactured in a different manner. In yet other examples, wheel <NUM> may be obtained rather than manufactured. Wheel <NUM> may be made of any suitable material. In some examples, wheel <NUM> includes a metal or a metal alloy. For example, wheel <NUM> may include aluminum, a nickel alloy, a steel alloy (e.g., stainless steel), titanium, a carbon-composite material, or magnesium.

Brake discs described herein, including brake disc <NUM>, rotor discs <NUM>, <NUM>, <NUM>, <NUM> and stator discs <NUM>, <NUM>, <NUM>, may be manufactured from any suitable material. In some examples, the brake discs described herein may be manufactured from a metal or a metal alloy, such as a steel alloy. In some examples, the brake discs may be manufactured from a carbon-carbon composite material. In some examples, the brake discs may be manufactured using a carbon-carbon composite material having a high thermal stability, a high wear resistance, and/or stable friction properties. The brake discs may include a carbon material with a plurality of carbon fibers and densifying material. The carbon fibers may be arranged in a woven or non-woven as either a single layer or multilayer structure. Surfaces and/or portions of brake disc <NUM>, such as central aperture <NUM>, disc outer perimeter <NUM>, disc slots <NUM>, <NUM>, friction surface <NUM>, disc first side <NUM>, disc second side <NUM>, first disc surface <NUM>, second disc surface <NUM>, third disc surface <NUM>, fourth disc surface <NUM>, first torque face <NUM>, second torque face <NUM>, and other surfaces and/or portions, may be formed using any suitable manner, such as machining.

Claim 1:
An assembly (<NUM>) comprising:
a rivet (<NUM>) defining a rivet head (<NUM>) attached to a rivet shank (<NUM>);
a washer (<NUM>) defining a washer hole (<NUM>); and
an insert (<NUM>) defining an insert ear (<NUM>) configured to cover a surface (<NUM>) of a brake disc (<NUM>) when the insert positions over a torque face (<NUM>) of a slot (<NUM>) on a perimeter (<NUM>) of the brake disc;
wherein the insert ear defines a rivet slot (<NUM>) extending through the insert ear,
wherein the rivet slot is configured to allow passage of the rivet shank through the rivet slot and into the brake disc to secure the insert to the brake disc,
wherein the washer is configured to be positioned between the rivet head and the insert ear when the rivet shank passes through the rivet slot and the washer hole and into the brake disc, and
wherein the rivet slot is configured to allow motion of the insert relative to the rivet in a tangential direction (T1, T2) of the brake disc when the rivet shank passes through the rivet slot and the washer hole and into the brake disc.