Patent Description:
Wrap around or U-channel stator clips are used to increase the structural capability of the stator disk(s) of a brake assembly, such as an aircraft brake assembly. In some cases, the increased strength is beneficial for loadings associated with in-service conditions. However, some disks are fully capable of handling required torque loadings in all cases except under extreme loading conditions that are rarely seen on an aircraft but are required for equipment certification.

The standard design for a stator clip is to extend proud of the carbon disk face such that the stator clip takes all the loading (by directly interfacing with the corresponding spline of the torque plate). Stator clips are commonly formed from sheet metal, resulting in relatively sharp edges that in turn are in contact with the torque plate splines. In some instances, this configuration leads to dynamic instability. Further, the use of stator clips has resulted in reduced braking performance at high aircraft landing energies. This is believed to be a result of stator clip drag on the corresponding torque plate spline. Brake assemblies are disclosed in <CIT>, <CIT> and <CIT>.

A stator disk assembly (e.g., for a brake assembly, for instance an aircraft brake assembly) is presented herein. Both the configuration of such a stator disk assembly and the operational characteristics / operation / assembly / manufacture of such stator disk assembly are within the scope of this Summary.

One aspect is directed to a stator disk assembly as defined by claim <NUM>.

The first and second wall portions of the first lug, along with a clip end wall of the first stator clip (disposed within the notch) may be defined by a common radius relative to the first reference axis.

The first lug that may be disposed between a first recess and a second recess (e.g., the first sidewall of the first lug defining a portion of a boundary for the first recess and the second sidewall of the first lug defining a portion of a boundary for the second recess). The first stator clip may be further configured so as to not protrude beyond the first sidewall of the first lug proceeding about the first reference axis in a direction of the first recess (e.g., an adjacent end of the first stator clip may be recessed or spaced back from the first sidewall of the first lug). Similarly, the first stator clip may be configured so as to not protrude beyond the second sidewall of the first lug proceeding about the first reference axis in a direction of the second recess (e.g., an adjacent end of the first stator clip may be recessed or spaced back from the second sidewall of the first lug). Such a configuration accommodates a spline of a torque plate engaging the stator disk (e.g., the first sidewall or the second sidewall of the first lug) during a braking operation without contacting the first stator clip.

Another aspect is directed to a brake assembly as defined by claim <NUM>.

Another aspect is directed to a method of reconfiguring a brake assembly as defined by claim <NUM>.

The subject matter of the present invention is particularly pointed out and distinctly claimed in the concluding portion of the specification. An understanding of the present disclosure may be further facilitated by referring to the following detailed description and claims in connection with the following drawings. Reference to "in accordance with various embodiments" in this Brief Description of the Drawings also applies to the corresponding discussion in the Detailed Description.

As used herein, a first component that is "radially outward" of a second component means that the first component is positioned at a greater distance away from a common axis (e.g., a rotational axis of a wheel assembly) than the second component. A first component that is "radially inward" of a second component means that the first component is positioned closer to the common axis than the second component. In the case of components that rotate about a common axis, a first component that is radially inward of a second component rotates through a circumferentially shorter path than the second component. As used herein, "distal" refers to the direction outward, or generally, away from a reference component. As used herein, "proximal" and/or "proximate" refer to a direction inward, or generally, towards the reference component. All ranges may include the upper and lower values, and all ranges and ratio limits disclosed herein may be combined. Unless specifically stated otherwise, reference to "a," "an" or "the" may include one or more than one and reference to an item in the singular may also include the item in the plural.

Referring to <FIG>, in accordance with various embodiments, an aircraft <NUM> is illustrated. The aircraft <NUM> includes landing gear, which may include a left main landing gear <NUM>, a right main landing gear <NUM> and a nose landing gear <NUM>. The landing gear support the aircraft <NUM> when it is not flying, allowing the aircraft <NUM> to taxi, take off and land without damage. While the disclosure refers to the three landing gear configurations just referred, the invention nevertheless contemplates any number of landing gear configurations.

Referring now to <FIG>, there is schematically depicted a brake assembly or a brake mechanism <NUM> that may be used by the aircraft <NUM> of <FIG> or any other appropriate aircraft. The brake mechanism <NUM> is mounted on an axle <NUM> for use with a wheel <NUM> disposed on and configured to rotate about the axle <NUM> via one or more bearing assemblies <NUM>. The wheel <NUM> includes a hub <NUM>, a wheel well <NUM> concentric about the hub <NUM> and a web portion <NUM> interconnecting the hub <NUM> and the wheel well <NUM>. A central axis <NUM> extends through the axle <NUM> and defines a center of rotation of the wheel <NUM>. A torque plate barrel <NUM> (sometimes referred to as a torque tube or barrel or a torque plate or back leg) is aligned concentrically with the hub <NUM>, and the wheel <NUM> is rotatable relative to the torque plate barrel <NUM>.

The brake mechanism <NUM> includes a piston assembly <NUM>, a pressure plate <NUM> disposed adjacent the piston assembly <NUM>, an end plate <NUM> positioned a distal location from the piston assembly <NUM>, and a plurality of rotor disks <NUM> interleaved with a plurality of stator disks <NUM> positioned intermediate the pressure plate <NUM> and the end plate <NUM>. The pressure plate <NUM>, the plurality of rotor disks <NUM>, the plurality of stator disks <NUM> and the end plate <NUM> together form a brake heat sink or brake stack <NUM>. The pressure plate <NUM>, the end plate <NUM> and the plurality of stator disks <NUM> are mounted to the torque plate barrel <NUM> and remain rotationally stationary relative to the axle <NUM>. Each stator disk <NUM> includes a pair of oppositely disposed sides 124a, 124b that each interface with a corresponding rotor disk <NUM> during a braking operation.

The torque plate barrel <NUM> may include an annular barrel or torque tube <NUM> and an annular plate or back leg <NUM>. The back leg <NUM> is disposed at an end distal from the piston assembly <NUM> and may be made monolithic with the torque tube <NUM>, as illustrated in <FIG>, or may be made as a separate annular piece and suitably connected to the torque tube <NUM>. The torque tube <NUM> has a plurality of circumferentially spaced and axially extending splines <NUM> disposed on an outer surface of the torque tube <NUM>. The plurality of stator disks <NUM> and the pressure plate <NUM> include notches or stator slots <NUM> on an inner periphery of the disks and the plate for engagement with the splines <NUM>, such that each disk and the plate are axially slidable with respect to the torque tube <NUM>.

The end plate <NUM> is suitably connected to the back leg <NUM> of the torque plate barrel <NUM> and is held non-rotatable, together with the plurality of stator disks <NUM> and the pressure plate <NUM>, during a braking action. The plurality of rotor disks <NUM>, interleaved between the pressure plate <NUM>, the end plate <NUM> and the plurality of stator disks <NUM>, each have a plurality of circumferentially spaced notches or rotor lugs <NUM> along an outer periphery of each disk for engagement with a plurality of torque bars <NUM> that is secured to or made monolithic with an inner periphery of the wheel <NUM>.

An actuating mechanism for the brake mechanism <NUM> includes a plurality of piston assemblies, including the piston assembly <NUM>, circumferentially spaced around an annular piston housing <NUM> (only one piston assembly is illustrated in <FIG>). Upon actuation, the plurality of piston assemblies affect a braking action by urging the pressure plate <NUM> and the plurality of stator disks <NUM> into frictional engagement with the plurality of rotor disks <NUM> and against the end plate <NUM>. Fluid or hydraulic pressure, mechanical springs or electric actuators, among other mechanisms, may be used to actuate the plurality of piston assemblies. Through compression of the plurality of rotor disks <NUM> and the plurality of stator disks <NUM> between the pressure plate <NUM> and the end plate <NUM>, the resulting frictional contact slows or stops or otherwise prevents rotation of the wheel <NUM>. The plurality of rotor disks <NUM> and the plurality of stator disks <NUM> are fabricated from various materials, such as ceramic matrix composites, that enable the brake disks to withstand and dissipate the heat generated during and following a braking action.

The torque plate barrel <NUM> is secured to a stationary portion of the landing gear such as the axle <NUM>, preventing the torque plate barrel <NUM> and the plurality of stator disks <NUM> from rotating during braking of the aircraft. The torque tube <NUM> portion of the torque plate barrel <NUM> may be attached to the annular piston housing <NUM> via an annular mounting surface <NUM>, wherein bolt fasteners <NUM> secure the torque plate barrel <NUM> to the annular piston housing <NUM>. A spacer member or pedestal <NUM> is positioned between an inner diameter surface <NUM> of the torque tube <NUM> and an outer diameter surface <NUM> of the axle <NUM>. The pedestal <NUM> includes a radially inner surface or foot <NUM> for engaging the axle <NUM>, a web portion <NUM> radially outward of the foot <NUM> and a head portion <NUM> for engaging the inner diameter surface <NUM> of the torque tube <NUM>. The pedestal <NUM> augments support of the torque plate barrel <NUM> within the brake mechanism <NUM> generally and, more particularly, against the axle <NUM>. The pedestal <NUM> may be made monolithic with the torque tube <NUM> portion of the torque plate barrel <NUM>.

A heat shield <NUM> is secured directly or indirectly to the wheel <NUM> between a radially inward surface of the wheel well <NUM> and the plurality of torque bars <NUM>. As illustrated in <FIG>, the heat shield <NUM> is concentric with the wheel well <NUM> and may have a plurality of heat shield sections <NUM> disposed between respective, adjacent pairs of the plurality of torque bars <NUM>. The heat shield <NUM>, or heat shield sections <NUM>, is spaced from the radially inward surface of the wheel well <NUM> and secured in place by heat shield tabs <NUM>, such that the heat shield <NUM>, or heat shield sections <NUM>, is disposed generally parallel to the axis of rotation or central axis <NUM> of the wheel <NUM> and intermediate the plurality of torque bars <NUM> and the radially inward surface of the wheel well <NUM>. In various embodiments, including for heavy-duty applications, the heat shield <NUM>, or heat shield sections <NUM>, may be further secured in place by heat shield carriers <NUM>.

The plurality of torque bars <NUM> is attached at axially inboard ends to the wheel <NUM> by torque bar bolts <NUM>. The torque bar bolts <NUM> extend through respective holes in a flange <NUM> provided on the wheel <NUM> as shown, which flange <NUM> for purposes of the present description is intended to be considered as part of the wheel well <NUM>. Each of the plurality of torque bars <NUM> may include a pin <NUM> or similar member at its axially outboard end (i.e., the end opposite the torque bar bolts <NUM>) that is received within a hole <NUM> disposed proximate the web portion <NUM> of the wheel <NUM>. The heat shield <NUM>, or heat shield sections <NUM>, is positioned adjacent a radially inward surface of the wheel well <NUM> and secured in place by the heat shield tabs <NUM>.

<FIG> illustrates a stator disk <NUM> that may be used as the stator disks <NUM> addressed above with regard to the brake assembly <NUM> of <FIG>. Although the stator disk <NUM> may be formed from any appropriate material or combination of materials, the stator disk <NUM> may be formed from carbon in various embodiments. An inner perimeter <NUM> of the stator disk <NUM> (or more generally for an inner perimeter <NUM> of a stator disk assembly that utilizes the stator disk <NUM>) is illustrated in <FIG>, is annularly disposed about a first reference axis <NUM> (e.g., extends a full <NUM>° about the axis <NUM>), and defines an outer boundary of a first aperture or a first mounting aperture <NUM> (e.g., for receipt of a torque plate). A plurality of lugs <NUM> are incorporated by the inner perimeter <NUM>, and these lugs <NUM> may be characterized as being disposed in radially-spaced or circumferentially-spaced relation to one another about/relative to the first reference axis <NUM>. A recess <NUM> is disposed between each adjacent pair of lugs <NUM>. As such, the stator disk <NUM> also includes a plurality of recesses <NUM> and these recesses <NUM> may be characterized as being disposed in radially-spaced or circumferentially-spaced relation to one another about/relative the first reference axis <NUM>. These lugs <NUM> and recesses <NUM> will be addressed in more detail below in relation to <FIG> and <FIG>. The stator disk <NUM> may include any appropriate number of lugs <NUM> and recesses <NUM>.

An outer perimeter <NUM> of the stator disk <NUM> is disposed outwardly of the inner perimeter <NUM>, relative to the first reference axis <NUM>. The stator disk <NUM> includes a first side <NUM> (e.g., corresponding with the first side 124a of one of the stator disks <NUM> shown in <FIG>), where this first side <NUM> may interface with a rotor disk during a braking operation. The stator disk <NUM> includes an oppositely disposed second side <NUM> (e.g., corresponding with the second side 124b of one of the stator disks <NUM> shown in <FIG>), where this second side <NUM> may interface with a different rotor disk during a braking operation. The thickness of the stator disk <NUM> corresponds with the spacing between these two sides <NUM>, <NUM>. Each of the first side <NUM> and second side <NUM> of the stator disk <NUM> include what may be characterized as a braking surface <NUM> that extends from an inner braking surface boundary <NUM> to the outer perimeter <NUM> of the stator disk <NUM>. Each braking surface <NUM> would engage a different corresponding rotor disk (e.g., rotor disk <NUM> - <FIG>) during a braking operation.

<FIG> illustrates a portion of a brake assembly <NUM> (e.g., brake assembly <NUM> of <FIG>) that includes the above-described stator disk <NUM>. Only an inward portion of the stator disk <NUM> (relative to the first reference axis <NUM>) is illustrated in <FIG>. The brake assembly <NUM> further includes a torque plate <NUM>. The torque plate <NUM> includes an outer surface <NUM> (e.g., a barrel) that is disposed about the first reference axis <NUM>. This outer surface <NUM> may be cylindrical. A plurality of splines, ribs, or protrusions <NUM> are disposed on the outer surface <NUM> of the torque plate <NUM>. The splines <NUM> may be disposed parallel with the first reference axis <NUM> and may be disposed about this same first reference axis <NUM> (e.g., the splines <NUM> may be characterized as being disposed in radially-spaced or circumferentially-spaced relation to one another about/relative the first reference axis <NUM>). Each spline <NUM> of the torque plate <NUM> is disposed in a corresponding recess <NUM> of the stator disk <NUM>. As such, typically the brake assembly will include an equal number of splines <NUM> (torque plate <NUM>) and recesses <NUM> (stator disk <NUM>).

What may be characterized as a stator disk assembly is illustrated in <FIG> and is identified by reference numeral <NUM>. The stator disk assembly <NUM> may be used by the brake assembly <NUM> of <FIG> and includes the above-noted stator disk <NUM> (<FIG>) and a plurality of stator clips <NUM>. A separate stator clip <NUM> may be mounted on each lug <NUM> of the stator disk <NUM>. The stator clip <NUM> includes a clip end wall <NUM> and a pair of clip sidewalls <NUM>, providing the stator clip <NUM> with a generally U-shaped body when viewed from an end of the stator clip <NUM>. The stator clip <NUM> may be an integral or monolithic structure, and may be formed from any appropriate material (e.g., steel, or more generally metallic - formed from one or more metals, one or more metal alloys, or a combination thereof).

As noted, a recess <NUM> is disposed between each adjacent pair of lugs <NUM> of the stator disk <NUM>. Each recess <NUM> may be characterized as including a base <NUM> (the base <NUM> being a surface of the stator disk <NUM>) that extends between its corresponding pair of lugs <NUM>. Each lug <NUM> includes a first sidewall <NUM>, a second sidewall <NUM>, and a lug end wall <NUM> (each of which is a surface of the stator disk <NUM>). Each stator clip <NUM> may be characterized as using a "saddle-type mounting" to the corresponding lug <NUM> of the stator disk <NUM>. In this regard, the clip end wall <NUM> of a stator clip <NUM> may be disposed over part of the lug end wall <NUM> of the corresponding lug <NUM>, one of the clip sidewalls <NUM> of the stator clip <NUM> may be disposed against/in proximity to the corresponding lug <NUM> on the first side <NUM> of the stator disk <NUM>, and the other of the clip sidewalls <NUM> of the stator clip <NUM> may be disposed against/in proximity to the corresponding lug <NUM> on the second side <NUM> of the stator disk <NUM>. Each stator clip <NUM> may be secured to the stator disk <NUM> in any appropriate manner, such as by one or more rivets <NUM> as shown in <FIG> and <FIG> (e.g., each rivet <NUM> may extend through one of the clip sidewalls <NUM> of the stator clip <NUM>, through the corresponding lug <NUM>, and through the other of the clip sidewalls <NUM> of the stator clip <NUM>).

<FIG> illustrates a portion of the stator disk assembly <NUM>. A first recess 232a is disposed between a first lug 236a and a first adjacent lug 236b, with the first recess 232a being defined by the first sidewall <NUM> of the first lug 236a, the second sidewall <NUM> of the first adjacent lug 236b, and the base <NUM> that extends between the first lug 236a and the first adjacent lug 236b. A second recess 232b is disposed between the first lug 236a and a second adjacent lug 236c, with the second recess 232b being defined by the second sidewall <NUM> of the first lug 236a, the first sidewall <NUM> of the second adjacent lug 236c, and the base <NUM> that extends between the first lug 236a and the second adjacent lug 236c.

Each stator clip <NUM> includes a first end or first clip end <NUM>, and an oppositely disposed second end or second clip end <NUM>. A maximum length of the stator clip <NUM> corresponds with the spacing between its corresponding first end <NUM> and its second end <NUM>, as measured proceeding about the first reference axis <NUM> (e.g., along an arcuate path). A length of the lugs <NUM> corresponds with the spacing between its corresponding first sidewall <NUM> and its corresponding second sidewall <NUM>, is also measured proceeding about the first reference axis <NUM> (e.g., along an arcuate path). The length of a given stator clip <NUM> is shorter than the length of the lug <NUM> on which the stator clip <NUM> is mounted.

The stator clip <NUM> may be characterized as being disposed entirely on its corresponding lug <NUM>. A portion of the lug end wall <NUM> may be exposed between the first end <NUM> of the stator clip <NUM> and the intersection of the lug end wall <NUM> with the first sidewall <NUM> of the lug <NUM>. Similarly, a portion of the lug end wall <NUM> may be exposed between the second end <NUM> of the stator clip <NUM> and the intersection of the lug end wall <NUM> with the second sidewall <NUM> of the lug <NUM>. The ends <NUM>, <NUM> of the stator clip <NUM> are those portions of the stator clip <NUM> that are closest to the intersection of the lug end wall <NUM> with the first sidewall <NUM> of the lug <NUM> and to the intersection of the lug end wall <NUM> with the second sidewall <NUM> of the lug <NUM>, respectively. The clip end wall <NUM> and part of each of the clip sidewalls <NUM> incorporate the ends <NUM>, <NUM> in the case of the stator disk assembly <NUM> of <FIG>.

Referring primarily to <FIG>, the stator clip <NUM> is positioned on its corresponding lug <NUM> such that this stator clip <NUM> does not protrude beyond the first sidewall <NUM> of the lug <NUM>, and furthermore does not protrude beyond the second sidewall <NUM> of the lug <NUM>. In <FIG>, the stator clip <NUM> is more specifically positioned on the lug <NUM> such that: <NUM>) the first end <NUM> of this stator clip <NUM> is spaced from the first sidewall <NUM> of the lug <NUM> proceeding about the first reference axis <NUM> in a direction of the second sidewall <NUM> of this lug <NUM> (represented by distance d); and <NUM>) the second end <NUM> of this stator clip <NUM> is spaced from the second sidewall <NUM> of the lug <NUM> proceeding about the first reference axis <NUM> in a direction of the first sidewall <NUM> of this lug <NUM> (also represented by distance d). Applicable values for the distance d include without limitation: <NUM>) a distance of at least about <NUM> inches (. <NUM>) (although other minimum spacings may be appropriate; <NUM>) a distance of no more than about <NUM> inches (<NUM>) (although other maximum spacings may be appropriate); and/or <NUM>) a distance within a range of about <NUM> inches (. <NUM>) to about <NUM> inches (<NUM>). The foregoing is applicable to each lug <NUM> and its corresponding stator clip <NUM>.

There are a number of features that relate to the above-noted positioning of the stator clips <NUM> relative to their corresponding lug <NUM>. The first sidewall <NUM> and second sidewall <NUM> of each lug <NUM> are exposed surfaces when the brake assembly <NUM> (<FIG> and <FIG>) is in an installed configuration. A corresponding spline <NUM> of the torque plate <NUM> that is disposed in a corresponding recess <NUM> of the stator disk <NUM> should engage either the first sidewall <NUM> of the second sidewall <NUM> of the corresponding recess <NUM> without engaging a stator clip <NUM> or any other structure (e.g., there may be a direct line-of-site from a spline <NUM> to the sidewall <NUM>, <NUM> of the corresponding adjacent pair of lugs <NUM>), including during a braking operation. Stated another way, contact between the splines <NUM> of the torque plate <NUM> and the stator disk assembly <NUM> should be limited to contact between the splines <NUM> and the stator disk <NUM> for at least certain conditions. Limiting contact to between the splines <NUM> (typically metal) and the stator disk <NUM> (e.g., carbon), versus with one or more stator clips <NUM> (e.g., metal), provides a number of benefits (e.g., improved dynamic stability; reduced dynamic instability; acceptable braking performance at high aircraft landing energies (for instance due to reduced clip drag on the torque plate <NUM>, more specifically its splines <NUM>)). What may be characterized as a "spline interface" for a given recess <NUM> of the stator disk <NUM> may be entirely defined by a first sidewall <NUM> of one lug <NUM> and a second sidewall <NUM> of an adjacent lug <NUM> (each of which is a surface of the stator disk <NUM>).

Under extreme loading conditions (e.g., conditions to be demonstrated as part of equipment certification, but unlikely to be realized in service), one or more lugs <NUM> of the stator disk <NUM> may start to crush by the noted interaction between a given lug <NUM> and a corresponding spline <NUM> of the torque plate <NUM>. The above-noted spacing d may be characterized as providing a "crush zone" - an amount of the stator disk <NUM> that can be "crushed" before there is contact between a given spline <NUM> and a corresponding stator clip <NUM> (e.g., before there is metal-to-metal contact, which may adversely impact the efficiency of braking performance or increase dynamic instability, which may result in brake-induced vibration).

A variation of the stator disk assembly <NUM> of <FIG> is presented in <FIG> and is identified by reference numeral <NUM>'. Corresponding components between the stator disk assembly <NUM> (<FIG>) and the stator disk assembly <NUM>' (<FIG>) are identified by the same reference numerals. Those corresponding components that differ in at least some respect are identified by a "single prime" designation for the stator disk assembly <NUM>'. Unless otherwise noted herein to the contrary, the foregoing discussion of components of the stator disk assembly <NUM> remains equally applicable to the corresponding component of the stator disk assembly <NUM>' (including those components of the stator disk assembly <NUM>' that differ in at least some respect from the corresponding component of the stator disk assembly <NUM>).

A recess <NUM> is disposed between each adjacent pair of lugs <NUM>' in the case of the stator disk assembly <NUM>', similar to the stator disk assembly <NUM>. In this regard and referring initially to <FIG> (illustrating a portion of the stator disk assembly <NUM>'), a first recess 232a is disposed between a first lug 236a' and a first adjacent lug 236b', with the first recess 232a being defined by the first sidewall <NUM> of the first lug 236a', the second sidewall <NUM> of the first adjacent lug 236b', and the base <NUM> that extends between the first lug 236a' and the first adjacent lug 236b'. A second recess 232b is disposed between the first lug 236a' and a second adjacent lug 236c', with the second recess 232b being defined by the second sidewall <NUM> of the first lug 236a', the first sidewall <NUM> of the second adjacent lug 236c', and the base <NUM> that extends between the first lug 236a' and the second adjacent lug 236c'.

The stator disk <NUM>' of the stator disk assembly <NUM>' differs from the above-discussed stator disk <NUM> of the stator disk assembly <NUM> primarily in relation to the lug end wall <NUM>' of each lug <NUM>'. As such, the inner perimeter <NUM>' of the stator disk assembly <NUM>'/stator disk <NUM>' also differs from the inner perimeter <NUM> of the stator disk assembly <NUM>/ stator disk <NUM>.

The lug end wall <NUM>' of each lug <NUM>' includes a notch <NUM>. This notch <NUM> is spaced from the intersection of the lug end wall <NUM>' and each of the sidewalls <NUM>, <NUM> of the corresponding lug <NUM>'. As such, there is a first end wall portion or section 248a between one end of the notch <NUM> and the intersection of the lug end wall <NUM>' with the first sidewall <NUM>. Similarly, there is a second end wall portion or section 248b between the opposite end of the notch <NUM> and the intersection of the lug end wall <NUM>' with the second sidewall <NUM>. A base <NUM> of the notch <NUM> is thereby offset (further radially outward from the first reference axis <NUM>) from each of the end wall portions 248a, 248b.

The stator clip <NUM>' of the stator disk assembly <NUM>' also differs from the stator clip <NUM> of the stator disk assembly <NUM> (<FIG>). The stator clip <NUM>' of the stator disk assembly <NUM>' of <FIG> again includes a clip end wall <NUM>' and a pair of clip sidewalls <NUM>', is at least generally U-shaped, may be an integral or monolithic structure, and may be formed from any appropriate material (e.g., steel, or more generally metallic - formed from one or more metals, one or more metal alloys, or a combination thereof). The stator clip <NUM>' also includes a first end or first clip end <NUM>', and an oppositely disposed second end or second clip end <NUM>'. A maximum length of the stator clip <NUM>' corresponds with the spacing between its corresponding first end <NUM>' and its second end <NUM>', as measured proceeding about the first reference axis <NUM> (e.g., along an arcuate path). In contrast to the stator clip <NUM> for the stator disk assembly <NUM> of <FIG>, the ends <NUM>', <NUM>' of the stator clip <NUM>' of the stator disk assembly <NUM>' of <FIG> are incorporated entirely by the clip sidewalls <NUM>'.

Referring primarily to <FIG>, the stator clip <NUM>' is positioned on its corresponding lug <NUM>' such that this stator clip <NUM>' does not protrude beyond the first sidewall <NUM> of the lug <NUM>', and furthermore does not protrude beyond the second sidewall <NUM> of the lug <NUM>'. In <FIG>, the stator clip <NUM>' is more specifically positioned on the lug <NUM>' such that: <NUM>) the first end <NUM>' of this stator clip <NUM>' is spaced from the first sidewall <NUM> of the lug <NUM> proceeding about the first reference axis <NUM> in a direction of the second sidewall <NUM> of this lug <NUM>' (represented by distance d); and <NUM>) the second end <NUM>' of this stator clip <NUM>' is spaced from the second sidewall <NUM> of the lug <NUM>' proceeding about the first reference axis <NUM> in a direction of the first sidewall <NUM> of this lug <NUM>' (also represented by distance d). Applicable values for the distance d again include without limitation: <NUM>) a distance of at least about <NUM> inches (. <NUM>) (although other minimum spacings may be appropriate; <NUM>) a distance of no more than about <NUM> inches (<NUM>) (although other maximum spacings may be appropriate); and/or <NUM>) a distance within a range of about <NUM> inches (. <NUM>) to about <NUM> inches (<NUM>). The foregoing is applicable to each lug <NUM>' and its corresponding stator clip <NUM>'.

Each stator clip <NUM>' is disposed in the notch <NUM> of its corresponding lug <NUM>'. An inner surface of the clip end wall <NUM>' may be disposed in closely-spaced and/or interfacing relation with the notch base <NUM> of its corresponding lug <NUM>'. The stator clip <NUM>' may be seated within its corresponding notch <NUM> such that one or more of the following applies: <NUM>) an outer surface of the clip end wall <NUM>' of the stator clip <NUM>' does not protrude beyond the first end wall portion 248a and the second end wall portion 248b of its corresponding lug <NUM>'; <NUM>) an outer surface of the clip end wall <NUM>' of the stator clip <NUM>' may be flush with the first end wall portion 248a and the second end wall portion 248b of its corresponding lug <NUM>' (e.g., such that the outer surface of the clip end wall <NUM>' and its corresponding end wall portions 248a, 248b are disposed a common distance from the first reference axis <NUM>); and/or <NUM>) an outer surface of the clip end wall <NUM>' of the stator clip <NUM>' and its corresponding end wall portions 248a, 248b may be defined by a common radius (e.g., emanating from the first reference axis <NUM>).

There are advantages associated with the integration of the stator clips <NUM>' with the stator disk <NUM>'. One is that the stator clips <NUM>' do not adversely impact or affect the surface area of the braking surface <NUM> of the stator disk <NUM>'. The surface area of the braking surface <NUM> on each side of the stator disk <NUM>' should be at least substantially the same as the surface area of the braking surface on each side of the stator disk <NUM> (<FIG>) when the stator clips <NUM> are not utilized for the lugs <NUM>. Another is that the stator clips <NUM>' remain sufficiently spaced from the corresponding portion of the outer surface <NUM> of torque plate <NUM> (<FIG>). That is, the diameter of the inner perimeter <NUM> of the stator disk <NUM> (<FIG>) may need to be increased when utilizing the stator clips <NUM> in the above-noted manner, which may reduce the braking surface <NUM> on each side <NUM>, <NUM> of the stator disk <NUM>. As such, the design of the stator disk assembly <NUM>' accommodates a retrofit.

A method of reconfiguring a brake assembly is illustrated in <FIG> and is identified by reference numeral <NUM>. A first stator disk may be removed from the brake assembly (<NUM>). A stator clip is mounted in a notch on a lug end wall of a lug of a second stator disk (<NUM>) - the second stator disk may be characterized as a replacement for the first stator disk. A stator clip may be mounted in the notch of the lug end wall of each lug of the second stator disk. In any case, the brake assembly may be reassembled using the second stator disk (<NUM>), for instance by disposing the second stator disk between an adjacent pair of rotor disks. The method <NUM> may of course be used for each stator disk of the brake assembly. It should be appreciated that the method <NUM> encompasses a retrofit or a refurbishment of the brake assembly with regard to its corresponding stator disks. The method <NUM> may be in accordance with the above-described stator disk assembly <NUM>'.

A method of reconfiguring a brake assembly is illustrated in <FIG> and is identified by reference numeral <NUM>. A stator disk may be removed from the brake assembly (<NUM>). A notch may be formed in a lug end wall of a first lug of the stator disk (<NUM>). Such a notch may be formed in the lug end wall of each lug of the stator disk. A stator clip may be mounted in the notch of the lug end wall of the first lug of the stator disk (<NUM>). A stator clip may be mounted in the notch of each lug of the stator disk (<NUM>, <NUM>). In any case, the brake assembly may be reassembled using the stator disk (<NUM>), for instance by disposing the stator disk between an adjacent pair of rotor disks. The method <NUM> may of course be used for each stator disk of the brake assembly. It should be appreciated that the method <NUM> encompasses a retrofit or a refurbishment of the brake assembly with regard to its corresponding stator disks. The method <NUM> may be in accordance with the above-described stator disk assembly <NUM>'.

Any feature of any other various aspects addressed in this disclosure that is intended to be limited to a "singular" context or the like will be clearly set forth herein by terms such as "only," "single," "limited to," or the like. Merely introducing a feature in accordance with commonly accepted antecedent basis practice does not limit the corresponding feature to the singular. Moreover, any failure to use phrases such as "at least one" also does not limit the corresponding feature to the singular. Use of the phrase "at least substantially," "at least generally," or the like in relation to a particular feature encompasses the corresponding characteristic and insubstantial variations thereof (e.g., indicating that a surface is at least substantially or at least generally flat encompasses the surface actually being flat and insubstantial variations thereof). Finally, a reference of a feature in conjunction with the phrase "in one embodiment" does not limit the use of the feature to a single embodiment.

The foregoing description has been presented for purposes of illustration and description. Furthermore, the description is not intended to limit the invention to the form disclosed herein. Consequently, variations and modifications commensurate with the above teachings, and skill and knowledge of the relevant art, are within the scope of the present invention, as in the appended claims. However, the benefits, advantages, solutions to problems, and any elements that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as critical, required, or essential features or elements of the invention. The scope of the invention is accordingly to be limited by nothing other than the appended claims, in which reference to an element in the singular is not intended to mean "one and only one" unless explicitly so stated, but rather "one or more.

Claim 1:
A stator disk assembly for a brake assembly, comprising:
a stator disk (<NUM>) comprising a plurality of lugs (<NUM>) disposed on an inner perimeter (<NUM>) of said stator disk, spaced about a first reference axis (<NUM>), said plurality of lugs comprising a first lug (236a), wherein said first lug comprises a lug end wall (<NUM>), a first sidewall (<NUM>) and a second sidewall (<NUM>), said first and second sidewalls each extending outwardly from said lug end wall relative to said first reference axis, and wherein said lug end wall comprises a notch; and
a first stator clip (<NUM>) disposed within said notch (<NUM>) of said first lug and mounted to said first lug, characterised in that said lug end wall comprises a first end wall portion (248a) and a second end wall portion (248b), wherein said notch extends between said first and second end wall portions, and wherein a clip end wall (<NUM>') of said first stator clip is flush with said first and second end wall portions of said first lug such that an outer surface of the clip end wall (<NUM>') and the corresponding outer surface of said first and second end wall portions are disposed a common distance from a first reference axis (<NUM>).