Brake Caliper Cover Fixing Disc for Secure Slip-Free Assembly
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Solution Overview
Problem
Existing brake caliper attachment solutions for disc brakes do not provide a secure and permanent fixation while allowing easy assembly, often leading to slippage and instability during assembly and operation.
Innovation Solution
A brake caliper design featuring a supporting structure with bridge fingers and a panel attached via a fixing disc with a clamping edge and cone system, providing form closure and stability through a combination of conical and cylindrical sections, and strategically placed cuts for enhanced clamping force and assembly ease.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a pin-shaped extension with frictional forces is used to attach the panel, then the assembly is simple, but the fixation is not secure and may slip during operation
Solution Approach 1:
The attachment system is divided into separate functional components: a conical insertion element for easy assembly, a fixing disc with clamping edge for secure fixation, and a grooved hole structure for positioning. This segmentation allows each component to perform its specific function optimally - the cone enables easy insertion while the clamping edge provides reliable retention.
Solution Approach 2:
The conical shape of the insertion element and the curved clamping edge provide favorable contact geometry. The cone shape guides assembly and distributes forces, while the circular course of the clamping edge ensures uniform contact pressure around the panel perimeter, preventing slippage.
2Ease of operation
If a screwless attachment method is used, then the assembly is simple and clean, but the permanent fixation is not achieved
Solution Approach 1:
The conical insertion element performs the preliminary action of guiding the panel into correct position and initiating the attachment sequence. The groove in the hole is pre-formed to receive the fixing disc, ensuring proper alignment before the final clamping action occurs.
Solution Approach 2:
The attachment system transitions from a loose insertion state to a firmly clamped state through the elastic deformation of the fixing disc. The clamping edge dynamically engages with the panel edge, creating increasing friction and mechanical interlocking as the disc is forced into the groove.
3Reliability
If the fixing disc is forced into the groove using an assembly tool, then the assembly is reliable, but the assembly process becomes more complex
Solution Approach 1:
The conical insertion element serves as an intermediary tool that combines the functions of alignment aid and forcing tool. By pushing the cone through the panel and into the hole, the assembly tool simultaneously positions the panel correctly and forces the fixing disc into the groove, eliminating the need for separate alignment and installation steps.
4Ease of operation
If the hole is tapered towards the brake pad side, then the assembly situation is favorable, but the structural strength of the hole is reduced
Solution Approach 1:
The hole structure is designed with different geometries in different zones: a tapered section at the insertion end for easy assembly and a cylindrical section at the retention end for structural strength. This local differentiation allows each zone to perform its specific function - the taper facilitates insertion while the cylindrical portion maintains structural integrity.
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
Ensures a secure, permanent attachment of the panel to the brake caliper, preventing slippage and facilitating easy assembly, while maintaining structural integrity and resistance to vibrations.
Implementation Method 1
the clamping area with the clamping edge counteracts an undesirable slip out of the tap from the hole
Implementation Method 2
The form closure between the fixing disc and hole, the fixing disc is kept in the hole in the hole in the axial direction along the bore length
Data Source
Figure 1~2
Figure 3~4
Figure 5~9
AI summary
The present invention relates to a brake caliper (1) for a disc brake comprising: - a support structure (2) with a bridge (3) and at least one bridge finger (4), which has a brake pad side (5), an outer side (6) and a bore (7) provided in the outer side (6) extending from the outer side (6) towards the brake pad side (5); - a cover (40) with a pin (43) projecting into the bore (7); - a fixing disc (20) with a disc edge (21) having an outer diameter D, which is positively engaged in the bore (7) and with a disc center (22) having a through-opening (25), in particular a circular through-opening (25), through which the pin (43) projects, wherein the disc center (22) has a clamping area (26) that is projecting towards the brake pad side (5) relative to the disc edge (21), which engages the pin (43) in the through-opening (25) with a clamping edge (27),in particular a circular clamping edge (27). The invention further relates to such a fixing disc (20).