Disc Brake Cover Interlock Structure to Prevent Caliper Detachment
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Solution Overview
Problem
The existing disc brake systems face issues with the adhesion of cover components to the caliper, leading to a risk of the cover components falling off, which affects the overall performance and reliability of the braking system.
Innovation Solution
The design incorporates a caliper with a cylinder portion, a bridge portion, a claw portion, and recessed portions with grooves, along with a plate member and interlock members that include folded interlock pieces to securely fix the cover component to the caliper, enhancing adhesion and preventing detachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a cover component is mounted on the caliper in a visible part, then the appearance is improved, but the adhesion is insufficient and the cover component may fall off
Solution Approach 1:
The caliper is divided into functional sections including a cover component mounting area. The cover component is separated as an independent part that can be mounted on the visible external surface of the caliper, allowing aesthetic customization while maintaining structural integrity through dedicated mounting features
Solution Approach 2:
The cover component is nested onto the caliper body, fitting over the external surface like a protective shell. This nesting arrangement allows the cover to enhance appearance while the interlock mechanism ensures secure attachment, preventing detachment during operation
2Reliability
If an interlock member with folded interlock pieces is used to fix the plate member, then the adhesion is improved, but the device complexity increases
Solution Approach 1:
The interlock member features folded interlock pieces that automatically engage with grooves on the caliper when the plate member is installed. This self-locking mechanism eliminates the need for separate fastening operations or additional fasteners, as the folded pieces themselves perform the securing function through their geometric configuration
Solution Approach 2:
The interlock pieces are designed with specific geometric parameters including fold angles, lengths, and positioning that enable them to deform and lock into the grooves. By optimizing these dimensional parameters, the mechanism achieves reliable adhesion while maintaining a relatively simple overall structure
Data Source
AI summary
This disc brake includes a first friction pad, a second friction pad, a piston, a caliper, a plate member, and an interlock member. The caliper has a cylinder portion, a bridge portion, a claw portion, and a recessed portion. The interlock member has a fixing portion which is fixed to the plate member, a first inward side folded interlock piece which extends in an axial direction of a cylinder hole from the fixing portion and in which a first inward side tip portion folded to an inward side of the cylinder hole in a radial direction abuts a groove, and a first outward side folded interlock piece which extends in the axial direction of the cylinder hole from the fixing portion and in which a first outward side tip portion folded an outward side of the cylinder hole in the radial direction abuts the groove.