Commercial Vehicle Disc Brake Pad Mounting Captive Bolt
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Solution Overview
Problem
The existing brake pad mounting systems for commercial vehicles are complex and costly to manufacture and assemble, with a high risk of fastening elements becoming detached during operation, leading to potential brake failure.
Innovation Solution
A brake pad mounting system with a securing bolt composed of two individual parts connected in a positively locking and/or non-positive manner, eliminating the need for a split pin, and featuring an expanding sleeve and pin configuration for secure axial connection, with optional threading and toothing systems for added stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the pad mounting bracket is fastened to the brake caliper using a securing bolt with split pin, then the connection is secure, but the manufacturing and assembly complexity increases and costs rise
Solution Approach 1:
The patent combines multiple fastening components (securing bolt and split pin) into a single integrated securing bolt design. The new securing bolt incorporates a head with an integrated locking mechanism that eliminates the need for a separate split pin, thereby reducing the number of individual parts while maintaining secure connection functionality.
Solution Approach 2:
The securing bolt is designed to perform multiple functions simultaneously: it provides mechanical fastening through the bolt shaft, creates a secure connection through the integrated head structure, and prevents detachment through built-in locking features. This multi-functional design replaces the need for separate components each performing specific fastening tasks.
2Reliability
If the pad mounting bracket is fastened using multiple individual parts (securing bolt, washer, split pin), then the connection is reliable, but the assembly process becomes more time-consuming and costly
Solution Approach 1:
The patent merges the securing bolt, washer, and split pin into a single integrated component. This consolidation reduces the number of assembly steps from multiple separate installations to a single installation operation, thereby increasing assembly speed and productivity while maintaining the same level of fastening reliability.
Solution Approach 2:
The securing bolt is segmented into functional zones (shaft portion for insertion, head portion for locking) that work together as an integrated unit. This segmentation allows each part of the single component to perform its specific function efficiently, replacing the need for multiple separate components and simplifying the assembly process.
3Ease of operation
If traditional fastening elements are used, then assembly is straightforward, but there is a risk that fastening elements become detached during operation
Solution Approach 1:
The securing bolt is designed with self-locking features where the head structure automatically secures itself to the pad mounting bracket during assembly. The integrated design ensures that the fastening element cannot become detached during operation, as the head portion creates a captive connection that prevents removal without tools, thereby enhancing reliability while maintaining ease of assembly.
Data Source
AI summary
A brake pad mounting is provided for a disc brake for a commercial vehicle, having a pad mounting bracket which is supported on pad holding springs of brake pads which are arranged in a brake caliper on both sides of a brake disc. The pad mounting bracket spans a mounting opening of the brake caliper in the axial direction of the brake disc and is held in a fastening socket of the brake caliper at least on one side by way of a securing bolt, is configured in such a way that the securing bolt consists of two individual parts which are connected to one another in a positively locking and/or nonpositive and/or integrally joined manner and, on the end side, have in each case one head which can bear against an associated side surface of the pad mounting bracket.