Brake Lining Back Plate Recess and Heat Shield
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing brake linings for vehicle disc brakes are complex to manufacture and prone to spring element weakening due to exposure to heat, requiring multiple production steps and complex design features like laterally angled tabs and punch openings.
Innovation Solution
The brake lining features a back plate with a recessed contour that allows for direct formation of support surfaces during casting, eliminating the need for bending and punching operations, and uses a hold-down device with a leaf spring shielded from heat, reducing manufacturing steps and enhancing durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If laterally angled tabs with punch openings are used to support the brake lining, then the brake lining can be secured in the lining shaft, but the manufacturing process becomes complex requiring multiple bending and punching operations
Solution Approach 1:
The support tabs are pre-formed as integral parts of the back plate during the casting process, eliminating the need for subsequent bending and punching operations. The tabs are created in advance with the correct geometry directly in the mold, simplifying manufacturing while maintaining securing functionality.
Solution Approach 2:
The support tabs are merged with the back plate as a single integral component rather than separate parts. This combination eliminates the need for additional assembly steps and reduces manufacturing complexity while maintaining the securing function of the tabs.
2Reliability
If punch openings are made in the tabs for inserting spring elements, then the brake lining can be secured against falling out, but the spring elements are exposed to heat from the brake disc and linings causing long-term weakening
Solution Approach 1:
A heat shield is introduced as an intermediary component between the spring element and the heat source (brake disc and linings). This shield blocks thermal radiation and conduction, protecting the spring element from heat exposure while allowing the securing function to remain effective.
Solution Approach 2:
The heat shield, which might seem like an additional complex component, actually simplifies the overall design by eliminating the need for heat-resistant spring materials or complex cooling mechanisms. It converts the harmful heat exposure into a manageable thermal barrier problem.
3Manufacturing precision
If multiple bending and punching operations are performed to create tabs and openings, then the brake lining can be properly constructed, but the manufacturing time and production steps increase
Solution Approach 1:
The tabs are pre-formed during the casting process itself, creating the necessary geometric features in advance. This preliminary action eliminates the need for subsequent bending and punching operations, significantly reducing manufacturing steps while maintaining precision.
Solution Approach 2:
The mechanical processes of bending and punching are replaced by a single casting operation. Instead of using mechanical force to deform and cut the metal, the desired tab geometry is created directly through mold casting, improving productivity while maintaining manufacturing precision.
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 design simplifies the manufacturing process, reduces the risk of spring element weakening, and provides reliable securing of the brake lining with improved resistance to heat and wear, ensuring consistent performance across various installation positions.
Implementation Method 1
spring elements arranged between the hold-down device and the brake pads
Implementation Method 2
the spring element inserted into the support tabs from above is exposed to the heat emanating from the brake disc and the brake linings during braking
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
Disk brake comprises a spring element (31) fixed to a brake caliper or housing on the outer side of a holding-down clamp (30). Preferred Features: Rear plates (5) are provided on the holding-down clamp with a recess (25) into which the clamp extends. The recess lies in the rear plates against the clamp. The recess has sides which lies against the clamp.