Heavy Vehicle Disc Brake Pad Retainer Integration
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Solution Overview
Problem
Existing disc brake systems for heavy vehicles require additional components for pad retention, which can lead to incorrect assembly, increased weight, and complexity, compromising safety and ease of maintenance.
Innovation Solution
Integration of a leaf spring into the brake pad for interaction with the mounting structure, providing compressibility and flexibility, and forming the resilient element with the backplate, allowing for secure and tool-free assembly and removal of brake pads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional components (retainer bolt and springs) are used for pad retention, then pad retention security is improved, but device complexity and weight increase
Solution Approach 1:
The patent combines the retainer function with the brake pad itself by integrating a retainer formation directly into the pad structure. This eliminates the need for separate retainer bolts and springs, reducing component count while maintaining retention security through the integrated design that works with the caliper's abutment surfaces.
Solution Approach 2:
The brake pad is given multiple functions: it provides friction material for braking, structural support through the backplate, and retention through the integrated retainer formation. This multi-functional design eliminates the need for dedicated retention components, reducing overall system complexity.
2Reliability
If additional components (retainer bolt and springs) are used for pad retention, then pad retention security is improved, but weight increases
Solution Approach 1:
The retainer function is merged into the brake pad structure itself, eliminating the need for separate retention components like bolts and springs. This integration directly reduces the overall weight of the brake assembly while maintaining retention security through the combined design.
3Reliability
If traditional retainer components are used, then pad retention is achieved, but ease of assembly is reduced due to tool requirements
Solution Approach 1:
The integrated retainer formation enables the brake pad to be retained and assembled through its own structural features working with the caliper abutments. This self-retaining design eliminates the need for external tools or complex assembly procedures, allowing for tool-free installation and removal.
4Reliability
If traditional retainer components are used, then pad retention is achieved, but manufacturing cost increases
Solution Approach 1:
The retainer function is combined with the brake pad manufacturing process itself. The retainer formation is created as an integral part of the pad during fabrication, eliminating the need for separate manufacturing and assembly of retention components, thereby reducing overall manufacturing cost.
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 solution simplifies the assembly and retention of brake pads, reduces the risk of incorrect assembly, and allows for cost-effective manufacturing while ensuring secure pad retention and easy maintenance, minimizing the risk of pad rattling and improving safety.
Implementation Method 1
a resilient element, which may comprise a leaf spring. The leaf spring may comprise at least a first curve in a first direction... This arrangement of leaf spring provides for compressibility / flexibility of the leaf spring
Data Source
Figure 1
Figure 2
Figure 3~3A
AI summary
A heavy vehicle disc brake, the heavy vehicle disc brake comprising first and second brake pads (69) 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 for selectively bringing the brake pads into contact with the rotor, and a first and a second brake pad support structures for restraining the first and second brake pads in a circumferential direction respectively, wherein at least one of the first and second brake pads comprises a moveable pad retainer formation (292) to permit assembly and retention of the brake pad in the support structure such that the brake pad is held within support structure for operation of the disc brake.