Disc Brake Retaining Bracket Fastening Without Caliper Machining
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Solution Overview
Problem
Existing disc brake designs require costly machining steps and complex assembly processes for securing elements, leading to increased production costs and potential loss or failure of the retaining bracket during use.
Innovation Solution
A disc brake design featuring a retaining bracket with a securing element that is elastically formable and interacts with the brake caliper, allowing for secure fastening without preloading, using wire springs, spring plates, or spring tongues to restrict axial movement and facilitate easy assembly and disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the retaining bracket is secured by threading a bolt into a threaded hole in the brake caliper housing, then the retaining bracket is held securely, but additional costly machining steps are required after casting
Solution Approach 1:
The securing element is designed with pre-formed engagement features (such as deformation zones, bending zones, or integral forming) that enable direct engagement with the brake caliper housing without requiring pre-drilled or pre-threaded holes. The securing element itself carries the threading or engagement structure, eliminating the need for subsequent machining operations on the brake caliper housing.
Solution Approach 2:
The securing element acts as an intermediary component between the retaining bracket and the brake caliper housing. It provides the threading and engagement features that would otherwise require expensive machining of the brake caliper housing, while still ensuring reliable securing of the retaining bracket.
2Reliability
If the retaining bracket is secured by inserting a split pin into a transverse bore or sliding a snap ring over a circumferential groove, then the holding bracket is fixed in position, but subsequent machining steps are necessary on the brake caliper housing
Solution Approach 1:
The securing element incorporates pre-formed engagement structures (deformation zones, bending zones, or integral forming features) that enable direct engagement with the brake caliper housing without requiring pre-drilled transverse bores or circumferential grooves. The securing element itself carries the necessary engagement geometry.
3Ease of operation
If the retaining bracket is divided into two parts connected by a manually operated tensioning mechanism, then quick assembly and disassembly is enabled, but both halves must be provided with corresponding designs increasing manufacturing costs
Solution Approach 1:
The securing element is designed as a separable component with distinct functional zones: a first section for engagement with the retaining bracket and a second section for engagement with the brake caliper housing. This segmentation allows the securing element to be manufactured separately and assembled quickly without requiring complex corresponding designs in both halves of a split retaining bracket.
Solution Approach 2:
The securing element serves as an intermediary that enables quick assembly and disassembly through its separable design, while concentrating the manufacturing complexity within the securing element itself rather than requiring corresponding complex designs in both the retaining bracket halves.
4Reliability
If the retaining bracket is divided into two parts secured by a locking pin, then the retaining bracket is secured in the middle, but there is a risk that the securing element will become loose and be lost during driving
Solution Approach 1:
The securing element is designed as an integrated unit where the first and second sections are connected through deformation zones, bending zones, or integral forming. This merging ensures that the securing element remains as a single piece that cannot be lost during driving, while still enabling quick assembly and disassembly through controlled deformation and recovery.
Solution Approach 2:
The securing element utilizes elastic deformation and recovery characteristics to provide dynamic securing. The deformation zones and bending zones allow the securing element to flex during assembly and disassembly, then return to their original shape to maintain a secure, loss-preventing connection during operation.
5Ease of operation
If circular slots or grooves are provided on both inside and outside of the brake caliper housing for rotating the retaining bracket, then the retaining bracket can be fixed by rotating, but extensive machining steps are required including milling of semi-circular grooves
Solution Approach 1:
The securing element incorporates pre-formed engagement features that eliminate the need for extensive machining of circular slots or grooves in the brake caliper housing. The securing element itself provides the necessary geometric features for rotational engagement and final fixing.
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 provides a cost-effective, reliable, and quick assembly process for the retaining bracket, ensuring secure attachment without additional machining and minimizing the risk of bracket loss or failure.
Implementation Method 1
a securing element (11, 20, 30, 37, 47, 58, 65) which is elastically formable and designed in such a way that it interacts with the retaining bracket (1, 21, 31, 39, 57, 62) and/or the brake caliper (2, 48, 59) in order to hold the retaining bracket (1, 21, 31, 39, 57, 62) relative to the brake caliper (2, 48, 59) in a form-fitting manner
Data Source
AI summary
The present invention relates to securing elements in various embodiments for securing a retaining bracket for tensioning brake linings in a lining shaft of a disc brake.