Brake Caliper Spring Unit for Low-Play Adjuster Latching
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Solution Overview
Problem
Existing brake calipers for vehicle disc brakes, particularly in commercial vehicles, face complexities in assembly and reliability due to the use of disc springs and retaining rings, which can fail and lead to assembly issues and increased manufacturing costs.
Innovation Solution
A brake caliper design featuring a spring unit with a latching element and adjuster unit in threaded engagement, providing resistance against rotational movement while eliminating play between components, simplifying assembly and reducing component count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If disc springs and retaining rings are used to eliminate play and provide turning resistance, then the play between thrust piece and adjuster unit is minimized, but the assembly complexity increases and reliability decreases
Solution Approach 1:
The patent combines the functions of eliminating play and providing turning resistance into a single integrated spring unit, replacing the separate disc spring and retaining ring components. This merging reduces assembly complexity while maintaining the necessary functional performance for reliable operation.
Solution Approach 2:
The spring unit is designed to perform multiple functions simultaneously: it eliminates play between components, provides turning resistance to prevent unwanted rotation, and maintains adjustable functionality. This multi-functionality reduces the number of separate components needed while ensuring reliable operation.
2Reliability
If multiple separate components (disc spring, retaining ring) are used to provide turning resistance and eliminate play, then sufficient functional performance is achieved, but manufacturing costs increase
Solution Approach 1:
The patent merges multiple separate components (disc spring and retaining ring) into a single integrated spring unit, reducing the total number of parts that need to be manufactured, inventoried, and assembled. This consolidation lowers manufacturing costs while maintaining the necessary functional performance through the multi-functional design of the spring unit.
3Reliability
If separate retaining ring with screws is used to couple with thrust piece, then turning resistance is provided, but assembly and disassembly become more difficult
Solution Approach 1:
The patent integrates the turning resistance function directly into the spring unit structure, eliminating the need for a separate retaining ring with screws. The spring unit itself provides the necessary resistance to rotational movement, greatly simplifying assembly and disassembly operations while maintaining reliable turning resistance.
Solution Approach 2:
The patent removes the complex retaining ring with screw connections from the assembly, extracting only the essential function of providing turning resistance, which is achieved more simply through the spring unit's design. This extraction eliminates unnecessary complexity while preserving the critical functional requirement.
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 enhances reliability and simplifies assembly while reducing manufacturing costs by combining functions and ensuring continued functionality even if one latching element fails, with a coaxially arranged spring unit and external thread latching interface for easy assembly and accessibility.
Implementation Method 1
a spring unit operatively coupled to the adjuster unit and the thrust piece and configured to apply a spring force in the axial direction between the thrust piece and the adjuster unit
Implementation Method 2
the latching element is arranged to engage the latching interface when the adjuster unit is in threaded engagement with the thrust piece
Implementation Method 3
the spring unit further has a mounting element in engagement with the thrust piece to provide a resistance against a rotational movement the adjuster unit relative to the thrust piece
Implementation Method 4
an adjuster unit in threaded engagement with the thrust piece
Data Source
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AI summary
The invention relates to a brake caliper (10) for a vehicle disc brake, in particular an air disc brake of a commercial vehicle, the disc brake having a pair of brake pads (20a, b), and a disc (30) positioned in between the brake pads (20a, b), the brake caliper (10) comprising: a thrust piece (110) that is configured to move at least one of the brake pads (20a, b) relative to the disc (30), an adjuster unit (200) in threaded engagement with the thrust piece (110), and a spring unit (300) operatively coupled to the adjuster unit (200) and the thrust piece (110). The invention suggests that the spring unit (300) has a latching element (310, 320, 330) and the adjuster unit (200) has a corresponding latching interface (220), wherein the latching element (310, 320, 330) is arranged to engage the latching interface (220) when the adjuster unit (200) is in threaded engagement with the thrust piece (110), and in that the spring unit (300) further has a mounting element (340) in engagement with the thrust piece (110) to provide a resistance against a rotational movement the adjuster unit (200) relative to the thrust piece (110).