Brake Caliper Pad Assembly With Pinless Sliding Support
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Solution Overview
Problem
Current brake calipers for disc brakes suffer from issues such as pin breakage and slippage, lack of space for efficient components, excessive weight due to steel pins, and complex maintenance processes, particularly during pad replacement.
Innovation Solution
The caliper body and brake pad assembly features machined sliding surfaces on the caliper body with support hooks on the pad support plates, allowing smooth sliding and torque discharge without pins, enabling efficient assembly and reduced wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If steel pins are used to support brake pads, then the caliper can maintain structural strength, but the caliper becomes excessively heavy
Solution Approach 1:
The patent removes the steel pins from the caliper structure entirely. Instead of using separate pin components, the caliper body incorporates integrated sliding surfaces directly into its structure, eliminating the need for discrete pin elements that add weight to the moving caliper assembly.
Solution Approach 2:
The patent merges the function of the pins with the caliper body itself by creating integrated sliding surfaces within the caliper structure. The support and sliding functions are combined into the caliper body rather than being separate components, reducing overall weight while maintaining structural integrity.
2Strength
If steel pins are used to support brake pads, then the caliper can maintain structural strength, but the pins breakage and slippage occur under heavy stresses
Solution Approach 1:
The patent removes the steel pins from the caliper structure entirely. Instead of using separate pin components, the caliper body incorporates integrated sliding surfaces directly into its structure, eliminating the need for discrete pin elements that add weight to the moving caliper assembly.
Solution Approach 2:
Instead of using separate pins that fit into the caliper body, the patent inverts the approach by having the caliper body itself provide the sliding surfaces. The support function is inverted from being provided by insertable pins to being provided by the caliper body's own structure.
3Strength
If steel pins are installed in the caliper, then the brake pad can be supported, but the available space for other components is reduced
Solution Approach 1:
The patent removes the steel pins from the caliper structure entirely. Instead of using separate pin components, the caliper body incorporates integrated sliding surfaces directly into its structure, eliminating the need for discrete pin elements that add weight to the moving caliper assembly.
Solution Approach 2:
The patent merges the function of the pins with the caliper body itself by creating integrated sliding surfaces within the caliper structure. The support and sliding functions are combined into the caliper body rather than being separate components, reducing overall weight while maintaining structural integrity.
4Strength
If traditional caliper assembly is used, then the brake pad can be supported, but the maintenance requires disassembly of the caliper
Solution Approach 1:
The patent segments the brake pad assembly from the caliper body by designing the brake pad as a removable component that can be accessed and replaced without disassembling the caliper body itself. The sliding surfaces are integrated into the caliper, allowing the pad to be independently serviced.
Solution Approach 2:
The patent designs the caliper with pre-integrated sliding surfaces that eliminate the need for pin installation during assembly. The structure is prepared in advance with built-in support surfaces, so maintenance only requires removing the brake pad itself rather than disassembling the entire caliper.
Data Source
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AI summary
The present invention relates to an assembly (1) of caliper body (2) and brake pads (3, 4). Said caliper body (2) comprises two pockets (5, 6) which receive the pads (3, 4). The caliper body (2) comprises two elongated elements (201, 202) and at least one central bridge (203) which crosses the two pockets (5, 6). Each brake pad (3, 4) comprises a support plate (11, 12) and friction material (13, 14) of predetermined radial extension (MAR). Each support plate (11, 12) comprises a support plate edge (17) having an upper edge portion (18) . Each support plate (11, 12) comprises at least one protuberance (19, 20) which projects from said upper edge portion (18) and is hook-shaped defining a plate sliding surface (21) indirectly facing said rotation axis (X-X). Each support plate (11, 12) comprises at least one pad support surface (22) arranged substantially orthogonal to said circumferential direction (C-C) which extends over at least half of the predetermined radial extension (MAR) of said friction material (13, 14). Said central bridge (203) comprises at least two central bridge protuberances (23) separated by a central bridge window (27) which form caliper body sliding surfaces (24) which face said plate sliding surfaces (21). The caliper body (2) comprises at least two caliper support surfaces (25, 26) which face said pad support surfaces (22) .