Utility Vehicle Disc Brake Elastomer Release Mechanism
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Solution Overview
Problem
Existing disc brake systems for commercial vehicles experience issues with residual grinding torque, brake overheating, increased friction lining wear, and uneven wear due to brake pads inadvertently contacting the brake disc during non-braking conditions, caused by lack of active release mechanisms.
Innovation Solution
Integration of elastically deformable elastomer components between the brake pads and brake carrier horns, which deform to exert a restoring force and actively return the brake pads to a neutral position, preventing unnecessary contact and wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If brake pads are pressed against the brake disc using an application device, then braking force is transmitted to the brake disc, but the brake pads remain in contact with the brake disc after braking is released, causing residual grinding torque and overheating
Solution Approach 1:
The brake pad assembly is designed with elastic deformable elements that allow dynamic adjustment of the brake pad position. After braking, the elastic elements actively push the brake pads away from the brake disc, creating a dynamic release mechanism that prevents continuous contact and eliminates residual grinding torque while maintaining firm contact during braking.
Solution Approach 2:
The elastic deformable elements in the brake pad assembly automatically perform the release function without external assistance. The system uses its own elastic components to self-regulate the brake pad position, pushing them away from the disc after braking and ensuring they return to the correct position for the next braking event.
2Ease of operation
If brake pads remain in contact with the brake disc after braking, then the brake pads are not actively moved away, but this causes continuous friction and overheating
Solution Approach 1:
The elastic deformable elements provide dynamic movement capability to the brake pads, enabling them to be actively pushed away from the brake disc after braking. This dynamic release mechanism prevents continuous contact, reducing friction-generated heat and avoiding overheating while maintaining simple automatic operation.
3Device complexity
If brake pads are not firmly connected to the application device, then the application device can be simple, but the brake pads are not actively moved away from the brake disc after braking
Solution Approach 1:
The elastic deformable elements are integrated into the brake pad assembly, providing a simple yet reliable connection mechanism. These elements maintain firm connection during braking while automatically releasing the brake pads after braking, achieving both structural simplicity and release reliability without complex additional mechanisms.
Solution Approach 2:
The elastic deformable elements automatically perform the release function without requiring complex external mechanisms. The system uses its own integrated elastic components to reliably push the brake pads away from the disc after braking, ensuring consistent release behavior while maintaining simple device structure.
4Manufacturing precision
If the neutral position of the brake lining moves towards the brake disc with increasing wear, then the brake pads may contact the brake disc more frequently, but the elastomer components must withstand greater expansion distances
Solution Approach 1:
The elastomer components are designed with variable elasticity parameters that adapt to wear conditions. As the brake lining wears and the neutral position moves closer to the brake disc, the elastomer components can withstand greater expansion distances while maintaining sufficient restoring force to push the brake pads away, ensuring continued effective operation throughout the service life.
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
Significantly reduces residual grinding torque, prevents brake overheating, and ensures even wear of brake linings by actively releasing the brake pads from the brake disc after braking, thus minimizing unnecessary wear.
Implementation Method 1
the elastomer components being positioned in such a way that an application movement of the brake pad towards the brake disc causes the elastic deformation and thus a restoring force of the elastomer components opposite to the application direction is increased
Data Source
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AI summary
A disc brake for a utility vehicle has a brake calliper which engages over a brake disc (2) and in which at least one brake lining (3), which can be pressed against the brake disc (2) and is mounted in a lining shaft of a positionally fixed brake carrier, is arranged, wherein, in order to support the enclosed brake lining, the lining shaft is bounded laterally by brake carrier lugs, with a brake application device which has at least one brake application plunger (5) which can be pressed against the brake lining (3), wherein the side faces (33), facing the brake carrier lugs, of the brake lining (3) and the brake carrier lugs adjacent to these side faces (33) are connected to one another by means of an elastically deformable elastomer component (4), wherein the elastomer components (4) are positioned in such a way that a brake application movement of the brake lining (3) towards the brake disc (2) increases the elastic deformation and therefore a restoring force of the elastomer components (4) which is opposed to the brake application direction. Furthermore, a brake lining for a disc brake is described.