Utility Vehicle Disc Brake Bellows Anchoring
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Solution Overview
Problem
Existing disc brake designs for commercial vehicles face challenges in cost-effectiveness and weight optimization due to complex and expensive production requirements for maintaining tight tolerances in the bellows and closure plate connection, which can lead to insecure sealing and reduced operational safety.
Innovation Solution
A disc brake design featuring a bellows securely anchored to the closure plate via injection molding, eliminating the need for tight tolerances and incorporating a reinforcement element to absorb compressive forces, thereby reducing weight and production complexity while ensuring a permanent seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If narrow diameter tolerances are observed in the collar area to achieve acceptable frictional connection, then the connection reliability is improved, but the manufacturing complexity and cost increase significantly
Solution Approach 1:
The patent replaces the mechanical friction-based connection (relying on narrow diameter tolerances) with a chemical bonding system. The bellows is molded directly onto the closure plate using injection molding or similar bonding processes, eliminating the need for precision-machined collars and friction-based retention. This substitution of mechanical retention with chemical bonding resolves the contradiction by achieving reliable connection without complex tolerance control.
Solution Approach 2:
The patent changes the fundamental connection parameter from friction-dependent (requiring narrow tolerances) to bond-dependent (allowing broader tolerances). By transitioning from a mechanical interference fit to a molded chemical bond, the system accepts larger dimensional variations while maintaining connection reliability, thus reducing manufacturing complexity.
2Strength
If the closure plate is designed with increased thickness to absorb braking forces, then the structural strength is improved, but the component weight increases
Solution Approach 1:
The patent segments the force-absorbing function from the sealing function. The closure plate is dedicated to sealing and structural integration, while a separate reinforcement element (such as a rib or stiffening structure) handles the braking forces. This segmentation allows the closure plate to remain thin and lightweight while still achieving the required strength through the added reinforcement feature.
Solution Approach 2:
The patent creates a composite structure by integrating the bellows (elastic material) directly with the closure plate (rigid material) through molding. This composite construction allows the thin closure plate to achieve enhanced strength and stiffness through the integrated design, reducing the need for additional thickness while maintaining force-absorbing capability.
3Ease of manufacture
If the bellows is secured to the closure plate by friction on a collar, then the assembly simplicity is improved, but the sealing reliability deteriorates due to loosening risks and gap formation
Solution Approach 1:
The patent merges the bellows and closure plate into a single integrated component through injection molding or similar bonding processes. This eliminates the separate collar and friction-based connection, creating a permanent bond that prevents loosening and gap formation. The merging of these components resolves the contradiction by achieving both assembly simplicity (as a single-piece design) and sealing reliability (through permanent bonding).
Solution Approach 2:
The patent uses a chemical bond (molded adhesive or integrated material) as an intermediary between the bellows and closure plate, replacing the mechanical friction interface. This intermediary creates a permanent, gap-free connection that maintains sealing reliability while simplifying the overall assembly process by eliminating the collar component.
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
The solution results in a cost-effective, lightweight disc brake with improved operational safety and extended service life, as the secure anchoring of the bellows prevents loosening and the reinforcement element minimizes the closure plate thickness, reducing weight and operating costs.
Implementation Method 1
a compression spring, which serves to push the traverse (20) and thus the brake plungers (4) into an end position when the brake is released, the compression spring being previously tensioned by compression during braking
Implementation Method 2
The bellows is fastened to the closure plate by friction, for which purpose the through-opening of the closure plate has an axially aligned circumferential collar on which the bellows made of an elastic material, usually an elastomer, lies flat.
Implementation Method 3
the bellows made of an elastic material, usually an elastomer
Data Source
AI summary
The invention relates to a disk brake for a utility vehicle, comprising a brake caliper (1) which is provided with a receiving chamber (12), which can be closed by a closure plate (2), for an application device . Said application device is provided with a traverse which can be moved which respect to the closure plate (2) and which is stressed by means of a brake lever and by a compression spring, in which at least one brake piston, which traverses a through opening (4) of the closure plate (2), is mounted, bellows (3) being maintained by the end region thereof, sealing the through opening (4) on the edge thereof also being connected to the brake piston. Said brake disk is designed in such a way that the bellows (3) is formed by injection on the closure plate (2) in the edge area (6) of the through opening (4) on the closure plate (2) and said closure plate (2) comprises, in the bearing area of the compression spring, a reinforcement element (5) which is connected to the brake caliper (1).