Cast-Iron Disc Brake Bridge With Parallel Parting Line

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Solution Overview

Problem

The existing cast-iron bridges in disc brakes for utility vehicles have a limited load-bearing capacity due to a thinner wall thickness in the load-bearing region, which is constrained by the installation space within the brake caliper.

Innovation Solution

The mold parting line is redesigned to run parallel to the outer edge of the bridge body, allowing for a thicker wall in the load-bearing region while maintaining the same installation space dimensions, thus optimizing the material distribution and reducing the overall weight and manufacturing costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the wall thickness in the load-bearing region is increased to improve load-bearing capacity, then the strength and service life of the bridge are improved, but the weight of the bridge increases significantly

Engineering Contradiction:

Improveload-bearing capacityVSAvoidweight of the bridge

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The bridge is designed with variable wall thickness where the load-bearing regions (near passage openings and outer edge) have increased wall thickness for strength, while non-critical regions have reduced wall thickness to minimize weight. This local differentiation optimizes the strength-to-weight ratio by concentrating material only where structurally necessary.

Inventive Principle:

Principle #3Local quality

2Strength

If the wall thickness is increased to improve load-bearing capacity, then the strength is improved, but the manufacturing cost increases due to greater material usage

Engineering Contradiction:

Improveload-bearing capacityVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The casting process is designed to create variable wall thickness with material concentrated only in load-bearing regions. This reduces overall material consumption compared to a uniformly thick design, lowering manufacturing costs while maintaining necessary strength through strategic material placement.

Inventive Principle:

Principle #3Local quality

3Strength

If the wall thickness is increased to improve load-bearing capacity, then the strength is improved, but the installation space requirements are exceeded

Engineering Contradiction:

Improveload-bearing capacityVSAvoidinstallation space

Core Design Contradiction:

StrengthVSVolume of moving object

Solution Approach 1:

The bridge utilizes variable wall thickness where thick sections are localized only to critical load-bearing areas near passage openings and the outer edge. Non-critical regions use thinner walls, allowing the overall component to fit within the constrained installation space of the brake caliper while providing sufficient strength where needed.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The design transitions from a uniform two-dimensional wall thickness to a three-dimensional variable thickness distribution, optimizing material placement in space to achieve both strength and compactness within the brake caliper installation envelope.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS20250075761A1Cast-Iron Bridge of a Disc Brake

Publication Date: 2025.03.06 KNORR BREMSE SYSTEME FUER NUTZFAHIZEUGE GMBH

AI summary

A disc brake component, includes: a cast-iron bridge having two passage openings, which are connected to one another by a bridge body and are each configured to receive an actuating spindle, wherein a mold parting line delimiting a draft angle is formed at a distance from an outer edge of the bridge body for manufacturing purposes, and the mold parting line runs parallel to a profile of the outer edge associated with the mold parting line of the bridge body.