Screwless Logo Fastening for Disc Brake Caliper Tolerance
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Solution Overview
Problem
Existing methods for attaching a company brand logo to the bridge fingers of a floating caliper in disc brakes often result in visible fastening elements, compromising aesthetics and failing to account for manufacturing tolerances.
Innovation Solution
A screwless fastening system using die-cast company logos with pins and sheet metal springs that are pressed into bores in the bridge fingers, allowing for tolerance compensation and invisible attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical fastening means (e.g., grooved nails, screws) are used to attach the company logo to the bridge fingers, then the attachment is secure and reliable, but the fastening elements become visible and compromise the aesthetic appearance
Solution Approach 1:
The fastening function is extracted from the visible logo area and transferred to the rear side of the logo. The spring clip fastens to the bridge fingers at the back, while the logo front remains clean and visible. This separates the fastening mechanism from the aesthetic display area, resolving the contradiction between secure attachment and visual appearance.
Solution Approach 2:
A spring clip serves as an intermediary fastening element that connects the logo to the bridge fingers. The spring clip has a front end that engages with the logo rear surface and a rear end that fastens to the bridge fingers. This intermediary component enables secure attachment while remaining hidden from the visible front view.
2Reliability
If rigid fastening means are used to attach the company logo, then the attachment is secure, but manufacturing tolerances in bore positions and logo pin positions cannot be compensated
Solution Approach 1:
The spring clip is designed with elastic properties that allow it to dynamically adapt to manufacturing tolerances. The spring arms can flex and deform elastically to accommodate misalignments between the logo pins and bore positions, while still maintaining secure attachment. This dynamic flexibility resolves the contradiction between secure fastening and tolerance compensation.
Solution Approach 2:
The spring clip's elastic modulus and geometric parameters are optimized to provide appropriate flexibility for tolerance compensation while maintaining sufficient clamping force for secure attachment. By adjusting the spring wire diameter, arm length, and cross-section, the fastening system adapts to varying tolerance conditions without compromising reliability.
3Strength
If visible fastening elements are used to attach the company logo, then the attachment method is recognizable and provides structural support, but the aesthetic quality of the brake assembly is compromised
Solution Approach 1:
The fastening function is extracted from the visible front area and relocated to the rear side of the logo. The spring clip performs all structural fastening operations at the back, engaging with the bridge fingers and securing the logo, while the logo front surface remains completely free of visible fastening elements, preserving aesthetic quality.
Solution Approach 2:
The spring clip acts as an intermediary that provides structural support and strength for logo attachment while remaining hidden from the visible front view. It transmits the fastening forces between the logo and bridge fingers without being perceived in the aesthetic display area, thus maintaining both strength and aesthetic quality.
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
Enables the secure, aesthetically pleasing attachment of a company brand logo to the bridge fingers of a floating caliper disc brake without visible fastening elements, accommodating manufacturing tolerances and ensuring the logo remains visually unobstructed.
Implementation Method 1
The sheet metal spring (7) is made of an elastic material and can be compressed in the compressed state in the longitudinal direction of the sheet metal spring
Data Source
Figure 1~3
Figure 4~5
Figure 6~7
AI summary
The spring element (7) has a cylindrical base body and spring arm, of which spring arm is bent in inward radial direction and the other spring arm is bent in outward radial direction. The spring arms are connected by a bar, which causes a movement directed radially inwards of the other feather arm, if the feather arm is pressed radially outwards. The spring arms are so formed that in fixing position the pins (9) are provided in the hole of the spring arm and the other spring arm is provided in the clamping contact with the walls of the hole and the pin. An independent claim is also included for a method for adjusting manufacturing tolerances of holes provided in a disc brake particularly a floating caliper, partial lining disk brake.