Brake Pad Liner Assembly for Mono Block Caliper Access

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Solution Overview

Problem

The assembly of brake devices, particularly those with opposing-type caliper bodies, is challenging due to complex shapes and limited access, leading to increased difficulty and reduced productivity in assembling brake pads and pad liners within the caliper body.

Innovation Solution

The design includes brake pads with protrusions that fit into guide grooves within the caliper body, a pad liner with a flat plate-type upper body and legs, and a return spring that supports the protrusions, facilitating easier assembly and maintaining a return force for reduced drag and noise during braking.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If the caliper body is of a mono block type with limited opening, then the structural integrity and simplicity of the brake device is improved, but the ease of assembly of brake pads and pad liners deteriorates

Engineering Contradiction:

Improvestructural integrityVSAvoidease of assembly

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

The brake pad is divided into multiple components: the pad body, pad liner, and protrusions that fit into guide grooves. This segmentation allows each component to be manufactured separately and assembled through the limited opening of the mono block caliper body, resolving the contradiction between structural integrity and ease of assembly.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The pad liner is inserted into the caliper body first, then the brake pad with its protrusions is inserted and nested around the pad liner. The protrusions fit into guide grooves within the caliper body, creating a nested assembly structure that can be assembled through the limited opening while maintaining the mono block design's structural integrity.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Reliability

If the pad liner has a complex shape to support brake pads properly, then the reliability of brake pad support is improved, but the ease of insertion of the brake pad into the caliper body deteriorates

Engineering Contradiction:

Improvebrake pad support reliabilityVSAvoidease of insertion

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The pad liner is segmented with legs extending downwards and a flat plate-type upper body, creating a simplified structure that is easier to insert into the caliper body while still providing reliable support for the brake pads through its geometric shape.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of making the pad liner complex to achieve proper support, the invention inverts the approach by using a simple geometric shape with legs and a flat plate that naturally provides the necessary support function, making insertion easier while maintaining reliability.

Inventive Principle:

Principle #13The other way round (Inversion)

3Manufacturing precision

If manual assembly of brake components is performed one by one, then the precision of component placement is improved, but the productivity of brake device manufacturing deteriorates

Engineering Contradiction:

Improvecomponent placement precisionVSAvoidmanufacturing productivity

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The brake pad and pad liner are designed to be assembled together as an integrated unit through the guide grooves and protrusions mechanism. This merging of assembly steps allows multiple components to be installed simultaneously through the limited opening, improving productivity while maintaining precise component placement through the guide groove geometry.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The guide grooves act as intermediaries that guide the protrusions during assembly, ensuring precise component placement automatically during the assembly process. This eliminates the need for manual positioning while maintaining manufacturing precision, thereby improving productivity.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 enhances assembly efficiency, ensures reliable return operation of the brake pads, reduces drag and noise, and simplifies maintenance by allowing easy detachment of brake pads from the caliper body.

Implementation Method 1

a return spring that supports the protrusions

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS20240384767A1Pad liner and brake device equipped with the pad liner

Publication Date: 2024.11.21 HYUNDAI MOBIS CO LTD

AI summary

A brake device includes an opposing-type caliper body, brake pads mounted in the caliper body, each pad liner that supports the brake pads, and each pad pusher that pushes each brake pad, wherein the brake pad includes protrusions protruding from both side surfaces thereof, wherein the caliper body includes each guide groove defined therein to guide each protrusion, wherein the brake pad moves guided by the guide grooves. The caliper body is of a mono block type.