Brake Caliper Spring Unit for Play Elimination and Turning Resistance
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Solution Overview
Problem
Existing brake calipers for vehicle disc brakes, particularly in commercial vehicles, face challenges with complex assembly and reliability issues due to the failure of disc springs and retaining rings, which can lead to entire assembly failure.
Innovation Solution
A brake caliper design featuring a spring unit with a latching element and an adjuster unit having a corresponding latching interface, which engages when threaded with the thrust piece, providing resistance against rotational movement and eliminating play, while reducing the number of components and manufacturing costs.
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 brake caliper achieves sufficient reliability and play elimination, but the assembly becomes complex and the number of components increases
Solution Approach 1:
The patent combines the functions of eliminating play and providing turning resistance into a single integrated spring unit, replacing the previous separate disc spring and retaining ring components. This merging reduces assembly complexity while maintaining the reliability benefits of both functions.
Solution Approach 2:
The spring unit is designed to perform multiple functions simultaneously: it eliminates play between the thrust piece and adjuster unit, provides turning resistance against rotational movement, and applies spring force. This multi-functionality reduces the total number of components needed while maintaining system reliability.
2Reliability
If multiple separate components (disc spring and retaining ring) are used to perform elimination of play and turning resistance, then the functions are adequately performed, but manufacturing costs increase and assembly is more difficult
Solution Approach 1:
The patent merges the disc spring and retaining ring into a single spring unit component that performs both functions. This integration simplifies manufacturing and assembly processes while maintaining the necessary functionality for play elimination and turning resistance.
Solution Approach 2:
The spring unit is designed as a universal component that simultaneously provides play elimination, turning resistance, and spring force application. This multi-functional design reduces the number of parts that need to be manufactured and assembled, improving ease of manufacture.
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 simplifies assembly, increases reliability, and reduces costs by combining the functions of eliminating play and providing resistance, ensuring the brake caliper's functionality even if one latching element fails, with a more accessible and evenly distributed spring force application.
Implementation Method 1
The spring unit is 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
an adjuster unit is in threaded engagement with the thrust piece
Data Source
AI summary
A brake caliper for a vehicle disc brake including a pair of brake pads, and brake a disc positioned in between the brake pads is provided. The brake caliper includes a thrust piece that is configured to move at least one of the brake pads relative to the brake disc, an adjuster unit in threaded engagement with the thrust piece, and a spring unit operatively coupled to the adjuster unit and the thrust piece. The spring unit has a latching element and the adjuster unit has a corresponding latching interface, wherein the latching element is arranged to engage the latching interface when the adjuster unit is in threaded engagement with the thrust piece, and 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.