Commercial Disc Brake Lining Locking for Rattle-Free Positioning
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Solution Overview
Problem
Existing disc brake systems for utility vehicles face challenges in operational reliability and cost due to complex manufacturing and mounting processes, with risks of component detachment and imprecise adjustments leading to noise and safety issues.
Innovation Solution
The system eliminates the need for lining securing springs and hoops by using dimensionally stable locking elements that provide radial support to the brake linings, secured to the brake carrier and engaging positively with the lining carrier plate, simplifying manufacturing and reducing costs while ensuring secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If lining securing springs and hoops are used to secure brake linings, then the brake linings can be held in position and tolerate manufacturing tolerances, but the device complexity increases and manufacturing costs rise
Solution Approach 1:
The invention extracts and eliminates the lining securing springs and hoops from the brake caliper assembly. Instead, the brake linings are directly secured to the brake carrier through integrated securing elements, removing the intermediate securing mechanism and simplifying the overall structure while maintaining positioning reliability
Solution Approach 2:
The invention merges the lining securing function directly into the brake carrier structure. The securing elements are integrated into the brake carrier rather than being separate components, combining multiple functions into a single structural element and reducing device complexity
2Strength
If multiple individual parts are used to attach the lining securing hoop to the brake caliper, then the hoop can be securely attached, but the manufacturing and mounting effort increases and costs rise
Solution Approach 1:
The invention combines multiple attachment parts into a single integrated securing element that is part of the brake carrier. This merging reduces the number of individual components from multiple separate parts to one unified structure, simplifying both manufacturing and assembly processes while maintaining attachment strength
Solution Approach 2:
The integrated securing element performs multiple functions simultaneously: it secures the brake lining, provides structural support, and interfaces with the brake caliper mounting system. This multi-functionality eliminates the need for separate dedicated attachment components
3Strength
If a threaded bore is made in the brake caliper to screw the lining securing hoop, then secure attachment is achieved, but manufacturing costs increase
Solution Approach 1:
The invention removes the threaded bore requirement from the brake caliper manufacturing process. The securing elements are designed to function without threaded connections, eliminating this costly manufacturing step while maintaining secure attachment through alternative mechanical engagement methods
4Strength
If the pocket-shaped receptacle and attachment eyelet are integrally formed in the cast iron brake caliper, then structural integrity is maintained, but fabrication tolerances cause imprecise positioning of the lining securing hoop
Solution Approach 1:
The invention extracts the positioning function from the integrally formed receptacle and eyelet structures. By removing these features and using direct securing elements on the brake carrier, the system avoids the positioning errors caused by integral forming tolerances while maintaining caliper structural integrity
Solution Approach 2:
The invention changes the positioning parameters from fixed integral features to adjustable securing elements that can accommodate tolerance variations. This allows for precise positioning despite variations in brake carrier dimensions
5Object-affected harmful factors
If lining securing springs are used to compensate tolerances and prevent rattling noises, then noise reduction is achieved, but the device complexity and cost increase
Solution Approach 1:
The invention extracts and eliminates the lining securing springs from the system. Instead of using elastic elements to dampen noise, the design achieves noise reduction through rigid mechanical connection of the brake linings to the brake carrier, preventing rattling without requiring additional spring components
Solution Approach 2:
The noise prevention function is merged into the primary securing mechanism itself. The same elements that secure the brake linings also prevent rattling noises, eliminating the need for separate noise-damping components
Data Source
AI summary
A disc brake and a brake lining for a commercial vehicle are provided. The disc brake includes a brake caliper on a stationary brake carrier and straddling a brake disc. The brake carrier has at least one brake lining space, in particular two brake lining spaces, each of which is delimited by lateral brake carrier lugs and accommodates a brake lining. At least one respective dimensionally stable blocking element is provided as a counter bearing against the insertion direction of the brake pads. The blocking elements are supported on the brake pads and/or or the brake carrier and are held on the brake carrier and/or on the brake pads.