Brake System Assembly With Rivet Clamping Against Material Separation
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Solution Overview
Problem
Existing assemblies for vehicle braking systems, particularly utility vehicles, face an insufficient holding effect due to all-around edge clamping geometry, leading to material separation between the assembly and internal components.
Innovation Solution
Incorporating a rivet-shaped second clamping feature that creates an opposing surface to the base element, enhancing the holding effect by increasing adhesion reactionary forces between internal components, and using injection molding to form the clamping features from the same material as the components, eliminating the need for external fasteners and simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If all-around edge clamping geometry is used, then the assembly can hold and fix internal components, but the holding effect is insufficient leading to material separation
Solution Approach 1:
The clamping feature is divided into two distinct parts: a first clamping feature for edge clamping and a rivet-shaped second clamping feature for penetrating fixation. This segmentation allows each part to perform its specific function optimally, with the rivet portion providing deep penetration into the base element for superior anchoring while the edge clamping portion maintains positional stability.
Solution Approach 2:
The solution transitions from two-dimensional edge clamping to three-dimensional fixation by adding the rivet-shaped portion that penetrates through the thickness of the base element. This dimensional extension creates opposing surfaces within the base element, establishing adhesion reactionary forces in the thickness direction that significantly enhance the holding effect and prevent material separation.
2Reliability
If additional clamping features are added to improve holding effect, then fixation is improved, but assembly complexity increases
Solution Approach 1:
The first clamping feature and the rivet-shaped second clamping feature are merged into a single integrated clamping feature formed in one manufacturing step. This integration eliminates the need for separate assembly operations, reduces the number of parts, and simplifies the overall assembly process while maintaining the dual-functionality of edge clamping and penetrating fixation.
Solution Approach 2:
The integrated clamping feature serves multiple functions simultaneously: it provides edge clamping for positional stability, penetrates the base element for deep anchoring, and creates opposing surfaces for adhesion reactionary forces. This multi-functionality eliminates the need for separate fasteners and simplifies the assembly structure.
3Ease of manufacture
If external fasteners are used for assembly, then components can be fixed, but assembly time and complexity increase
Solution Approach 1:
The clamping feature with rivet-shaped portion is pre-formed as an integral part of the assembly during the molding process. This preliminary formation eliminates the need for subsequent fastening operations, allowing the assembly to be completed in a single injection molding step and significantly reducing assembly time and complexity.
Solution Approach 2:
The assembly structure is designed to self-fix the internal components through the integrated clamping feature that automatically penetrates and anchors into the base element during the molding process. This self-service mechanism eliminates the need for external fasteners and manual assembly operations, streamlining the manufacturing process.
Data Source
AI summary
An assembly for a braking system for a vehicle, in particular utility vehicle is provided. The assembly is adapted for holding and fixing at least a first component and a second component, and the assembly includes a base element and a first clamping feature, arranged so that at least one edge area of said first component and/or said second component is clamped by said first clamping feature. To improve the fixation and clamping of the internal components, said assembly also includes at least a rivet-shaped second clamping feature. The base element, the first clamping feature, and the rivet-shape second clamping feature may be integrally formed via injection molding around and/or through the first and second component.