New 3D floating rotor that solves overheating and deformation of bicycle brake systems

Equipping bikes with a high performance and robust braking system ensures a safe and smooth riding experience.

However, the use of hydraulic disc brakes as the new standard in cycling is hampering this expectation by causing an increase in problems.

To solve these problems, the Taiwanese company PSB bike launched the two-piece 3D floating rotoran innovative long-term solution to deal with the menacing unpredictability of today’s braking systems.


Overheating and deformation of the rotor.

Overheating and rotor warping are two problems caused by hydraulic discs that pilots cannot control.

Most rotors on the market deform to varying degrees under constant braking, and many do not return to their flat state after cooling.

Adding to safety concerns, the current disc system rubs against the brake pad, creating abnormal noise. The Floating Rotor 3D therefore hopes to solve these problems.

The problem is that when hydraulic fluid is sent from the brake lever to the caliper to push the pistons, it is difficult to ensure that the caliper maintains even thrust after prolonged use. As the caliper moves, the uneven thrust of the pistons will directly bend the rotor. Obviously, the most common problem in this case is disc warping, so a floating disc could be the solution.

Rotor with floating and elastic properties.

The proposed rotor design stands out from other designs due to its elastic and floating outer disc.

The floating function is achieved by spring-loaded rivets at the rear of the rotor, which create isolation between the outer and inner discs.

Meanwhile, the open cuts on the 6th and 12th ribs give the rotor its elastic property. In this way, the disk is not only deformable horizontally, but also vertically.

Unique angular cuts allow support when the margin deviation reaches the set value along the direction of force during braking. Open cuts do not affect blade strength.

These characteristics allow the disc to move and deform over 85% more distance than conventional floating rotors. The structure also puts the strength of this 1.8 millimeter thick rotor on par with other 2mm rotors.

Thus, the braking problem and rotor deformation caused by heat can be effectively avoided, providing riders with safety and security when braking.

In addition, uneven caliper tightening is avoided, ensuring optimum braking performance and extending the life of the brake disc and pads. Frame resonance noise is also reduced.

The design of the PSB Bike is able to respond to the braking forces of e-bikes as well, making it a unique solution on the market. The 3D floating rotor won the Red Dot Product Design Award and the 2022 iF Design Award.

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