Brake Caliper Pad Retainer Form-Fit Attachment

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Solution Overview

Problem

Existing disc brake systems face challenges in simple and cost-effective assembly and disassembly of brake pads, with previous fastening methods being cumbersome and costly, especially in cramped spatial conditions.

Innovation Solution

A disc brake design featuring a pad retainer with a window opening for form-fit engagement of a locking tongue, which secures the pad retainer against displacement, combined with positive locking elements on the brake caliper and a latching tongue on the pad retaining spring or hood, allowing for secure attachment without additional connecting means.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional fastening methods (screws, threaded holes) are used to secure the pad retainer to the brake caliper, then the attachment reliability is improved, but the assembly complexity and manufacturing cost increase significantly

Engineering Contradiction:

Improveattachment reliabilityVSAvoidassembly complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The pad retainer is divided into a retainer body and separate form-fit elements (lugs or tabs) that can be independently formed. This segmentation allows the fastening function to be separated from the main retainer structure, enabling simple attachment to the brake caliper without requiring complex threaded holes or multiple fastening components in the caliper itself.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The form-fit elements are designed as simple, inexpensive features that can be easily formed into the retainer body through stamping or molding. These elements serve their fastening purpose reliably but can be easily replaced if needed, avoiding the need for expensive, complex fastening systems in the brake caliper.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Strength

If additional connecting means (screws, fasteners) are introduced to secure the pad retainer, then the attachment strength is improved, but the manufacturing cost and assembly time increase

Engineering Contradiction:

Improveattachment strengthVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The form-fit elements are merged directly into the retainer body as an integrated feature, eliminating the need for separate connecting means such as screws or fasteners. This merging reduces the total part count, simplifies manufacturing, and lowers costs while maintaining adequate attachment strength for the application.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The retainer body itself provides the fastening function through its integrated form-fit elements, eliminating the need for additional connecting means. The structure is self-sufficient, performing both the retainer and fastening functions without requiring external fastening components.

Inventive Principle:

Principle #25Self-service

3Reliability

If the brake caliper is modified with threaded holes or fastening features, then the pad retainer attachment reliability is improved, but the manufacturing cost and spatial requirements increase

Engineering Contradiction:

Improveattachment reliabilityVSAvoidcaliper manufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Instead of modifying the brake caliper with threaded holes or fastening features (the traditional approach), the invention inverts the approach by providing form-fit elements on the pad retainer itself that engage with simple recesses or surfaces on the caliper. This reverses the complexity from the caliper to the retainer, where it is much easier and cheaper to manufacture.

Inventive Principle:

Principle #13The other way round (Inversion)

4Ease of operation

If form-locking elements are used instead of connecting means, then the assembly simplicity is improved, but the attachment robustness under maximum stress may be compromised

Engineering Contradiction:

Improveassembly simplicityVSAvoidattachment robustness

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The form-fit elements are designed with appropriate flexibility and engagement geometry to provide dynamic attachment that is both simple to assemble and robust under stress. The elements can accommodate minor misalignments during assembly while maintaining secure engagement during brake operation, balancing simplicity with reliability.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentEP2895764B1Arrangement of a pad retaining clip on the brake caliper of a disk brake, and brake pad

Publication Date: 2018.11.14 KNORR BREMSE SYSTEME FUER NUTZFAHIZEUGE GMBH

Figure 1
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Figure 3~4

AI summary

The invention relates to a brake caliper (1) of a disk brake. Two brake pads, which can be pressed onto a brake disk (2) on both sides and which each have a lining carrier plate (5) and a friction lining (6) fastened thereto, are arranged in the brake caliper (1). The pad retaining clip (8), which is retained on the brake caliper (1) and which spans an installation opening (19), is supported on the brake pads. The pad retaining clip (8) is fastened to a form-closure element of at least one brake pad (4) so as to be secured against movement.