Disc Brake Sheet Metal Ring for Bellows Heat Shielding
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Solution Overview
Problem
Existing disc brake systems for commercial vehicles face challenges in effectively protecting the bellows from heat radiation and maintaining structural integrity under deformation forces, leading to increased overall length and potential damage to the cohesive connection between the sheet metal plate and ring.
Innovation Solution
A sheet metal arrangement with a reduced bending stiffness sheet metal ring, made of spring steel and featuring a cylindrical and annular disk-shaped section, is designed to deform elastically, protected by a heat-resistant coating, and connected to the sheet metal plate via a circumferential weld or adhesive joint, with recesses to reduce bending rigidity and a non-stick disk to prevent sticking and further reduce heat radiation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a rigid sheet metal ring is used to protect the bellows from heat radiation, then the thermal protection is improved, but the structural integrity at the connection point deteriorates due to increased deformation forces
Solution Approach 1:
The sheet metal ring's bending stiffness is adjusted by modifying its cross-sectional geometry (changing from a rigid circular section to an oval or flattened section with reduced moment of inertia). This parameter change allows the ring to flex under deformation forces, protecting the connection point while maintaining sufficient thermal barrier properties
Solution Approach 2:
A coating layer is applied to the sheet metal ring to create a composite structure. The coating provides enhanced thermal insulation or heat reflection properties, allowing the base sheet metal ring to be made with reduced stiffness while maintaining adequate thermal protection performance
2Reliability
If additional pressure pieces are attached to protect the brake pad carrier plate, then the structural protection is improved, but the overall length of the disc brake increases
Solution Approach 1:
The protective function previously requiring separate pressure pieces is merged into the sheet metal ring structure itself. The sheet metal ring serves dual purposes: protecting the bellows from heat radiation and providing structural support/protection for the brake pad carrier plate area, thereby eliminating the need for additional separate components that would increase overall length
Solution Approach 2:
The sheet metal ring is designed to perform multiple functions simultaneously: thermal protection of the bellows, structural support for the brake assembly, and protection of the brake pad carrier plate area. This multi-functionality consolidates what would otherwise require multiple separate components into a single integrated element
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 effectively protects the bellows from heat radiation, maintains the structural integrity of the connection point, and prevents damage during deformation, while ensuring the bellows do not stick and reducing heat radiation, thus enhancing the disc brake's performance and longevity.
Implementation Method 1
The sheet metal ring (9) is arranged between a bellows (5) and a brake pad (2a) to protect the bellows from heat radiation generated by the brake pad
Implementation Method 2
The sheet metal ring preferably has at least partially a heat-resistant, in particular heat-reflecting coating
Implementation Method 3
the sheet metal ring is made of spring steel... designed to deform elastically... converting a force introduced into the sheet metal ring into a deformation of the sheet metal ring
Implementation Method 4
The sheet metal plate and the sheet metal ring are joined together by welding or gluing
Implementation Method 5
The sheet metal plate and the sheet metal ring are joined together by welding or gluing
Data Source
Figure 1~2
Figure 3~5
AI summary
A disc brake for a vehicle, having a first and a second brake lining (2a), and a brake disc (1) which is arranged between them, and a brake calliper which engages over the brake disc (1) with a brake calliper housing (6), in which a brake application device is arranged, wherein the brake application device comprises a pressure piece (3) which can be applied against the first brake lining (2a), wherein a boot (5) is provided for protecting the interior of the brake calliper housing against contaminants, wherein the boot (5) is fastened by way of a first end region (5a) to the brake calliper housing (6) and by way of a second end region (5b) to a sheet metal arrangement (7) consisting of a sheet metal plate (8) and a sheet metal ring (9) which is arranged coaxially with respect thereto and is connected in an integrally joined manner to said sheet metal plate (8), wherein the sheet metal plate (8) is arranged between an end side of the pressure piece (3) and the first brake lining (2a), wherein the sheet metal ring (9) is arranged between the boot (5) and the brake lining (2a) for protecting the boot (5) against heat radiation which is generated by way of braking operations on the brake linings (2a, 2b) and the brake disc (1), and wherein the sheet metal ring (9) has at least one cut-out (11) for reducing its flexural stiffness.