Brake Application Device Heat Shield for Commercial Vehicles

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Solution Overview

Problem

Existing brake application devices for commercial vehicles face issues with the boot inflating and sticking to the pressure plate due to high temperatures, leading to crack formations and frequent replacements, especially with high-temperature materials that are expensive and have low crack resistance.

Innovation Solution

A heat shield is positioned between the pressure plate head and the boot with a spacing to prevent direct heat transfer, using an insulating layer and a metal ring encapsulated or coated with an elastomer to absorb heat and prevent sticking, reducing the need for high-temperature materials and minimizing heat transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If high temperature material is used for the boot, then resistance to heat and sticking is improved, but crack resistance and service life deteriorate

Engineering Contradiction:

Improveheat resistanceVSAvoidcrack resistance

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

A heat shield is introduced as an intermediary component between the brake disc and the boot. The heat shield absorbs and blocks heat transfer to the boot, allowing the boot to be made from conventional materials with good crack resistance rather than expensive high-temperature materials. This mediator protects the boot from thermal damage without requiring the boot material itself to have high temperature resistance.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Temperature

If high temperature material is used for the boot, then heat resistance is improved, but cost increases

Engineering Contradiction:

Improveheat resistanceVSAvoidcost

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The heat shield serves as a cost-effective intermediary that protects the boot from heat. This allows the use of conventional, lower-cost boot materials instead of expensive high-temperature materials, significantly reducing manufacturing costs while maintaining adequate heat protection.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Temperature

If heat shield is arranged completely over the pressure plate surface, then heat protection is improved, but sticking to pressure plate occurs

Engineering Contradiction:

Improveheat protectionVSAvoidsticking prevention

Core Design Contradiction:

TemperatureVSEase of operation

Solution Approach 1:

The heat shield is designed with local quality by providing heat protection only in the critical areas where heat transfer occurs, rather than covering the entire pressure plate surface. This localized approach maintains adequate thermal protection while preventing the heat shield from sticking to the pressure plate during braking operations.

Inventive Principle:

Principle #3Local quality

4Temperature

If heat shield is placed in direct contact with pressure plate, then heat transfer is improved, but sticking occurs due to heat

Engineering Contradiction:

Improveheat transferVSAvoidsticking

Core Design Contradiction:

TemperatureVSObject-affected harmful factors

Solution Approach 1:

The harmful effect of direct heat transfer is extracted and managed by positioning the heat shield at a specific distance from the pressure plate. This spacing prevents the heat shield from sticking to the pressure plate while still providing adequate heat protection to the boot, separating the heat shield from direct thermal contact with the pressure plate.

Inventive Principle:

Principle #2Taking out (Extraction)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution effectively prevents the boot from sticking to the pressure plate, reduces heat transfer, and extends the lifespan of the heat shield, avoiding premature cracking and costly replacements while maintaining safety standards.

Implementation Method 1

the heat shield being arranged between the pressure plate head and the heat shield at a spacing X... the heat transfer of the brake disc between the pressure plate and the heat shield is interrupted by way of the spacing

Methodology Applied

Scientific EffectHeat absorption: Absorption (EM radiation)

Implementation Method 2

A heat shield is positioned between the pressure plate head and the boot with a spacing to prevent direct heat transfer, using an insulating layer

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 3

The elastomer absorbs the radiated heat from the brake disc and protects the boot from sticking or, in other words, protects against fusing of the metal ring with the pressure plate as a result of the radiated heat of the brake disc

Methodology Applied

Scientific EffectHeat absorption: Absorption (EM radiation)

Data Source

PatentUS11441627B2Disc brake and brake application device for commercial vehicles

Publication Date: 2022.09.13 ZF CV SYST EURO BV

AI summary

A brake application device (1) for a disc brake (2) of commercial vehicles comprising an actuating spindle (3) with, axially of the actuating spindle (3), a pressure plate (4) arranged on the actuating spindle (3), and the pressure plate (4) having an annular groove (6) radially for receiving a boot (5). A heat shield (7) is at least partially disposed between the pressure plate head (4a) and the boot (5) at a spacing (X). An insulating layer (8) may be present between the heat shield (7) and the pressure plate head (4a). The heat shield (7) may be a metal ring (10) encapsulated in or coated with an elastomer (9a). The heat shield (7) may alternatively be formed of plastic or silicone.