Disc Brake Pad Guide Geometry to Prevent Reversed Pad Installation

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Solution Overview

Problem

Conventional vehicle disc brakes face issues with incorrect installation of friction pads, where tabs can be inserted into pad guide grooves even when the pads are reversed, leading to potential misalignment and braking inefficiencies.

Innovation Solution

The implementation of an incorrect installation preventing mechanism, including caliper side recesses or protrusions and tab side protrusions or recesses, which prevent tabs from being inserted into pad guide grooves when the pads are installed in an incorrect orientation, ensuring proper alignment by bumping against the caliper body or tabs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If friction pads are designed with tabs that can be inserted into pad guide grooves, then the friction pads can be easily installed and supported movably in disc axial direction, but the friction pads can be incorrectly installed in reversed orientation

Engineering Contradiction:
Improveease of installationVSAvoidinstallation correctness
Core Design Contradiction:
Ease of operationVSReliability

Solution Approach 1:

The patent applies asymmetry by providing different structures on the disc entry side and disc exit side of the friction pad tabs. Specifically, one tab has a protrusion while the corresponding pad guide groove has a recess, creating an asymmetric configuration that prevents incorrect installation. This asymmetric design ensures that tabs can only be inserted into the correct pad guide grooves in the proper orientation, eliminating the possibility of reversed installation while maintaining ease of installation through the simple tab-and-groove interface.

Inventive Principle:
Principle #4Asymmetry

2Device complexity

If simple tab and groove structures are used for supporting friction pads, then the device complexity is reduced, but incorrect installation cannot be prevented

Engineering Contradiction:
Improvestructure simplicityVSAvoidinstallation correctness
Core Design Contradiction:
Device complexityVSReliability

Solution Approach 1:

The patent introduces minimal asymmetric features (protrusions and recesses) into the otherwise simple tab and groove structure. This approach maintains the overall simplicity of the device while adding just enough complexity to the tab-groove interface to prevent incorrect installation. The asymmetric protrusion-recess configuration is easily manufactured and integrates seamlessly into the existing simple structure, achieving reliability enhancement without significant increase in device complexity.

Inventive Principle:
Principle #4Asymmetry

3Reliability

If protrusions and recesses are added to prevent incorrect installation, then installation correctness is improved, but the device complexity increases

Engineering Contradiction:
Improveinstallation correctnessVSAvoidstructure complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies local quality by concentrating the anti-incorrect-installation features (protrusions and recesses) only at specific critical locations on the tabs and pad guide grooves, rather than throughout the entire friction pad structure. This localized approach ensures installation correctness through targeted asymmetric features while minimizing the overall complexity increase. The protrusions and recesses are positioned only where needed to prevent misalignment, keeping the rest of the simple tab-and-groove structure intact.

Inventive Principle:
Principle #3Local quality

Data Source

PatentUS11668358B2Vehicle disc brake
Publication Date: 2023.06.06 NISSIN KOGYO CO LTD
  • US11668358B2 patent drawing
  • US11668358B2 patent drawing
  • US11668358B2 patent drawing

AI summary

The present invention is a vehicle disc brake for which incorrect installation of a friction pad can be prevented with a simple structure. The disc brake is provided with incorrect installation-preventing parts with which, if a friction pad (4) is installed with an incorrect installation orientation when a pair of tabs (10, 11) provided on the disc entry-side and disc exit-side of the back plate (4d) of a friction pad (4) is installed into pad guide grooves (9) formed on a caliper body (3), the tabs bump into the caliper body (3) and prevent the incorrect installation. The incorrect installation-preventing parts are formed from caliper-side recesses (9d, 9e), which are formed in the pad guide grooves (9) towards the center of the caliper body, and tab-side protrusions (10a, 11a), which have shapes that correspond to the caliper-side recesses (9d, 9e).