Disc Brake Caliper Structure Without a Separate Brake Carrier

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Solution Overview

Problem

Disc brakes for commercial vehicles face challenges with high intrinsic weight and increased manufacturing costs due to the need for a large brake carrier and additional components, which also occupy valuable installation space.

Innovation Solution

The integration of projections within the brake caliper to accommodate brake pads eliminates the need for a separate brake carrier, allowing for a lighter, more compact design with reduced production costs and additional space utilization.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a brake carrier with separate brake pad carrier is used, then the brake pads can be properly supported and positioned, but the overall weight of the disc brake increases to at least 9 kg

Engineering Contradiction:

Improvebrake pad support and positioningVSAvoidoverall weight of disc brake

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The patent merges the brake pad carrier function directly into the brake caliper by integrating projections (9, 9a, 9b, 9c) that form pad carrier recesses (10, 10a) within the caliper body. This eliminates the separate brake carrier component while maintaining the support and positioning function for brake pads, thereby reducing overall weight.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The brake caliper is designed to perform multiple functions: it provides structural support, houses the clamping device, and simultaneously serves as the brake pad carrier through its integrated projections. This multi-functionality eliminates the need for separate dedicated components, reducing weight while maintaining reliability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If a brake carrier and additional components are used to support brake pads, then proper pad positioning is achieved, but manufacturing costs increase

Engineering Contradiction:

Improvebrake pad positioningVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

By combining the brake pad carrier projections directly into the brake caliper structure, the number of separate components is reduced. This simplifies the manufacturing process and reduces assembly steps, thereby lowering manufacturing costs while maintaining proper pad positioning through the integrated projections.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The separate brake carrier component is extracted from the system and its functionality is integrated into the existing brake caliper. This eliminates the need for manufacturing and assembling a separate carrier component, reducing overall manufacturing complexity and cost.

Inventive Principle:

Principle #2Taking out (Extraction)

3Reliability

If a brake carrier and additional components are used, then brake pads can be secured, but the installation space occupied increases

Engineering Contradiction:

Improvebrake pad securingVSAvoidinstallation space

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The brake pad securing function is merged into the brake caliper structure through integrated projections. This eliminates the need for a separate brake carrier that would occupy additional installation space, while still providing secure brake pad positioning through the caliper's own structural features.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The brake caliper serves as both the clamping mechanism housing and the brake pad carrier simultaneously. This multi-functional design eliminates the need for additional dedicated space for a separate carrier component, optimizing the use of installation space while maintaining secure pad securing.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Volume of stationary object

If a narrow clamping unit design is used, then space within the brake caliper increases, but the clamping device dimensions are reduced

Engineering Contradiction:

Improveclearance within brake caliperVSAvoidclamping device dimensions

Core Design Contradiction:

Volume of stationary objectVSLength of moving object

Solution Approach 1:

The clamping device is designed with a narrow, segmented structure that reduces its overall dimensions while maintaining functional effectiveness. This segmentation allows for more efficient space utilization within the brake caliper, creating additional clearance for integrated features like the projections and pad carrier recesses.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The design transitions towards a more compact, radially-oriented clamping unit rather than a lengthy axial design. This dimensional change optimizes space utilization within the caliper volume, freeing up space for the integrated brake pad carrier projections while maintaining effective clamping function.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentEP3835612B1Disc brake, especially for commercial vehicles and vehicle comprising a disc brake, especially a commercial vehicle comprising a disc brake

Publication Date: 2022.08.24 ZF CV SYST EURO BV

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AI summary

The invention relates to a disc brake, particularly for commercial vehicles, comprising a brake caliper and brake pads for clamping the brake disc, wherein the brake caliper has a first interior space with an opening on the side facing the brake disc for receiving a clamping device, and the brake caliper has a second interior space for receiving the brake disc. The object of the invention is to provide a disc brake with a brake caliper and brake pads that offers space-saving advantages, is lightweight, and reduces manufacturing costs.