Heavy Vehicle Disc Brake Pad Mounting for Jam-Free Fitting
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Solution Overview
Problem
Existing disc brake systems for heavy vehicles face challenges in pad retention and foolproof fitting, particularly in radial orientations that can lead to jamming and incorrect orientation during installation, which complicates the replacement process and does not provide sufficient functional benefits.
Innovation Solution
The design incorporates brake pads with complementary circumferential profiles that allow for insertion at an angle and pivoting about a fixed center, ensuring secure fitting and reduced likelihood of jamming, along with a smaller and simpler pad retainer, and a backplate with stiffening ribs to enhance structural integrity and noise reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If brake pads are fitted radially inward/outward via a radial opening, then pad replacement can occur without removal of the brake caliper, but the arrangement is prone to jamming and does not provide foolproof fitting
Solution Approach 1:
The patent inverts the conventional radial fitting approach by implementing circumferential insertion with angular pivoting. Instead of moving radially inward/outward, the brake pad is inserted circumferentially and then pivoted about a fixed center point, fundamentally changing the motion path to eliminate jamming issues associated with radial movement through confined openings.
Solution Approach 2:
The patent transitions from one-dimensional radial movement to a two-dimensional insertion path involving circumferential movement followed by angular pivoting. This dimensional change allows the pad to be installed without passing through a restrictive radial opening, thereby eliminating jamming while maintaining ease of replacement.
2Ease of manufacture
If conventional radial fitting is used, then installation is simple, but incorrect orientation fitting cannot be prevented
Solution Approach 1:
The patent employs asymmetric complementary profiles on the brake pad and mounting structure that only mate in the correct orientation. The circumferential insertion path combined with the specific angular pivoting requirement creates an inherently asymmetric installation process that prevents incorrect orientation, while the profiles are designed to guide the pad automatically into the correct position during insertion.
Solution Approach 2:
The complementary circumferential profiles and angular pivoting mechanism provide self-aligning and self-correcting features during installation. The geometry of the profiles automatically guides the brake pad into the correct orientation as it is being inserted, eliminating the need for separate alignment steps or complex positioning procedures.
3Reliability
If standard pad retainers are used, then pad retention is achieved, but the retainers are large and complex
Solution Approach 1:
The patent extracts the retention function from a complex separate retainer mechanism and integrates it directly into the mounting structure through the complementary circumferential profiles. The retention is achieved through the geometric interlocking of the pad profiles with the mounting structure, eliminating the need for bulky external retainers while maintaining secure pad retention.
Data Source
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AI summary
A heavy vehicle disc brake, the disc brake comprising first and second brake pads (11A) for selectively contacting opposing inboard and outboard faces of a brake rotor respectively, a brake caliper for confining the first and second brake pads in at least an inboard-outboard direction, an actuation mechanism housed within the brake caliper for selectively bringing the brake pads into contact with the rotor, and a first and a second brake pad support structures (75A, 75B) for restraining the first and second brake pads in a circumferential direction respectively, wherein at least one of the first and second brake pads and the corresponding first and second support structures comprise complementary profiles on circumferential faces thereof arranged so as to permit the brake pad to be inserted into the mounting structure in a transverse direction (T) of the pad and at an angle to the circumferential direction of the structure and then for the brake pad to be pivoted about a fixed centre of rotation when a circumferential surface of the brake pad is in contact with a complementary circumferential surface of the structure to be brought into a fitted position in the structure.