Brake Caliper Protective Panel Design for Debris Protection
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Solution Overview
Problem
Disk brakes on vehicles face damage from road debris and require a robust, visually appealing design that effectively protects components without compromising functionality.
Innovation Solution
The housing finger, spring element, and protective panel are arranged axially, with the spring element positioned between the housing finger and protective panel, forming a caliper panel that covers a significant part of the spring arrangement, and a fastening device ensures a constant spacing to prevent component collision and wear-induced movement of the protective panel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a protective panel is added to cover the spring arrangement, then protection against road debris is improved, but device complexity increases
Solution Approach 1:
The protective panel is merged with the caliper housing to form an integrated caliper panel that serves both as structural housing and protective covering. The spring arrangement is integrated within the housing structure, with the protective panel forming part of the housing itself, eliminating the need for separate protective components.
Solution Approach 2:
The caliper panel serves multiple functions: it acts as the housing structure for the brake caliper, provides protection against road debris, and serves as a mounting surface for the spring arrangement. This multi-functional design reduces overall device complexity while maintaining protective capabilities.
2Reliability
If the protective panel is fixed rigidly to prevent movement, then protection reliability is improved, but ease of repair deteriorates
Solution Approach 1:
The protective panel is designed as a separable component that can be divided into removable sections. The caliper panel can be detached from the housing, allowing the spring arrangement to be accessed and replaced independently while maintaining the protective function of the remaining panel structure.
Solution Approach 2:
The fastening device allows the protective panel to transition between a fixed state during operation (providing reliable protection) and a removable state for maintenance (enabling easy panel exchange). The dynamic fastening system maintains security during use while facilitating quick removal when needed.
3Productivity
If the spring arrangement is made compact to reduce space, then productivity is improved, but device complexity increases
Solution Approach 1:
The spring arrangement is nested within the caliper housing structure, with the spring element positioned in a recess or cavity formed in the housing. This nesting allows the spring mechanism to be compact while maintaining its elastic preload function, as the housing itself provides the structural framework.
Solution Approach 2:
The spring element is designed as a flexible elastic component that can be positioned in a compact configuration within the housing. The flexible nature of the spring allows it to provide sufficient preload force in a reduced space, maintaining brake response efficiency without requiring a complex multi-component assembly.
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
This configuration provides comprehensive protection and visual harmonization of the disk brake, preventing damage from road debris and allowing for easy panel exchange to maintain the brake's appearance and functionality.
Implementation Method 1
a spring arrangement which generates an elastic preload between the brake caliper and the bracket
Data Source
AI summary
A disk brake for a vehicle having a bracket which is fixed with respect to the vehicle and on which brake linings and at least one brake caliper are mounted so as to be movable in an axial direction is disclosed. The bracket and the brake caliper engage around at least one brake disk, and the brake caliper includes a housing limb with at least one actuating device, a further housing limb with at least one housing finger, and a housing bridge. A spring arrangement which generates an elastic preload between the brake caliper and the bracket is provided in such a way that the preload is aligned substantially perpendicular to a movement direction of the brake caliper. The spring arrangement comprises a spring element and a protective panel.