Disc Brake Bellows Sealing via Form-Fit Latching
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Solution Overview
Problem
Disc brakes face issues with maintaining a secure sealing effect due to loose frictional connections between bellows and closure caps, leading to potential corrosion and increased production costs from tight tolerances required for a stable press fit.
Innovation Solution
A form-fit connection between the stiffening ring and closure cap, with axially extending latching tabs engaging in latching openings, ensures a secure hold of the bellows without the need for precise diameters and surface finishes, allowing for a more relaxed tolerance and reduced production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a friction fit connection between bellows and closure cap is used, then the bellows can be sealed in the receiving space, but the connection becomes loose due to relative movement, causing the bellows to migrate and lose sealing effect
Solution Approach 1:
The connection system is segmented into multiple functional elements: the collar structure with groove, the stiffening ring with latching tabs, and the bellows. The latching tabs engage with the groove to provide form-fit connection, while the bellows material provides friction fit. This segmentation allows each element to perform its specific function and prevents bellows migration.
Solution Approach 2:
The connection interface uses a composite approach combining rigid elements (collar, stiffening ring with latching tabs) and elastic elements (bellows made of elastomer or elastomer-metal composite). The rigid form-fit connection prevents migration while the elastic bellows maintain sealing through friction fit and deformation capability.
2Stability of the object's composition
If tight tolerances are applied to the collar diameter and surface finish to ensure secure press fit, then the bellows connection becomes stable, but production costs increase significantly
Solution Approach 1:
The invention changes the connection parameters from relying on tight dimensional tolerances to relying on the geometric form-fit provided by the groove and latching tabs. The collar diameter tolerance can be relaxed because the latching tabs engage with the groove to prevent migration, eliminating the need for extremely precise press fit dimensions.
Solution Approach 2:
The stiffening ring with latching tabs acts as an intermediary element between the collar and the bellows. It mediates the connection by providing the form-fit engagement that prevents migration, allowing the collar and bellows to have relaxed tolerances while maintaining connection stability.
3Adaptability or versatility
If the bellows is made entirely of elastomer to allow relative movement, then flexibility is achieved, but the connection area lacks stability and requires additional stiffening measures
Solution Approach 1:
The bellows structure implements local quality by having different properties in different regions. The main body of the bellows remains entirely of elastomer for flexibility and relative movement, while the connection area incorporates a stiffening ring for local stability and form-fit engagement. This localized reinforcement allows the bellows to be entirely elastomeric while preventing connection area deformation.
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
This design enhances operational reliability and service life by maintaining a permanent seal, reduces production costs, and allows for easier implementation and replacement of components, while preventing bellows damage and enabling the use of cheaper anti-corrosion coatings.
Implementation Method 1
provision is made for the stiffening ring to be provided with axially extending latching tabs which engage in latching openings provided on the collar of the closure cover
Implementation Method 2
an end region of the bellows bears exclusively with a friction fit on the inside of which an end region of the bellows bears exclusively with a friction fit
Data Source
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AI summary
The disk brake comprises a brake caliper (1), in which two brake shoes (4) are arranged pressable in function against a brake disk (3). An adjustable spindle (10) is provided, which is guided by a cover plate (7) closing a receiving space of the brake caliper towards the brake disk. A reinforcement ring is provided, which is fixed on the cover plate in a form-fit manner.