Disc Brake Cover Locking Structure for Easier Caliper Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The assembly of a cover component to a caliper in disc brakes is not efficiently facilitated, leading to increased complexity and potential design, productivity, and durability issues.
Innovation Solution
A disc brake design that includes a cover member and a locking member with inclined locking pieces, which are separate from the cover member, allowing for easier assembly by providing an elastic force to secure the cover member to the caliper, featuring a cover member that covers recessed parts and locking members with fixing parts and locking pieces extending to contact the inner surface of the recessed parts with an elastic force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a cover member is integrated with the caliper body, then structural strength is improved, but manufacturing complexity and assembly difficulty increase
Solution Approach 1:
The caliper is divided into separate components: the caliper body and the cover member. The cover member is a distinct piece that covers the recessed part of the caliper body, allowing for easier manufacturing and assembly while maintaining structural integrity through the locking mechanism with locking pieces.
2Ease of manufacture
If the cover member is made as a single integrated piece, then manufacturing simplicity is improved, but assembly ease deteriorates
Solution Approach 1:
The cover member is designed as a separate component from the caliper body, enabling independent manufacturing of each part. This segmentation allows for optimized manufacturing processes for each component while the locking mechanism ensures easy and secure assembly.
3Ease of operation
If locking pieces are provided separately from the cover member, then assembly ease is improved, but device complexity increases
Solution Approach 1:
The locking pieces are integrated into the cover member as a unified structure rather than being separate components. This merging reduces the total number of parts while maintaining the ease of assembly through the elastic locking mechanism that engages with the caliper body.
4Device complexity
If the locking pieces extend in a direction parallel to piston movement, then structural simplicity is improved, but assembly ease deteriorates
Solution Approach 1:
The locking pieces are designed to extend in a direction inclined at an angle θ (0 < θ < 90°) relative to the piston movement direction. This dynamic angular configuration allows the locking pieces to engage smoothly with the caliper body during assembly, reducing assembly difficulty while maintaining structural simplicity.
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 configuration simplifies the assembly process, enhances design flexibility, improves productivity, and increases durability by reducing the force required for assembly and preventing disengagement, while also reducing weight and stabilizing the cover component's fixed state.
Implementation Method 1
a plurality of locking pieces extending from the fixing part in a direction inclined with respect to a movement direction of the piston to come into contact with an inner surface of the recessed part with an elastic force
Data Source
AI summary
This disc brake includes a mounting member, a pair of brake pads, a caliper, a cover member, and a locking member. The caliper includes a cylinder part having a cylinder hole in which a piston for moving one of the pair of brake pads is disposed, a bridge part extending across an outer circumferential surface of a disc from the cylinder part, a plurality of claw parts formed on an extended distal end side of the bridge part and disposed to face the cylinder part, and a recessed part provided between the plurality of claw parts, having an opening at a disc radial direction inner end, and formed to face the cylinder hole. The locking member includes a fixing part fixed to the cover member, and a plurality of locking pieces extending from the fixing part in a direction inclined with respect to a movement direction of the piston.