Disc Brake Pressure Element for Even Brake Liner Force Distribution
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing disc brake systems face inefficiencies in force transmission, particularly in electromechanically actuated brakes, where the actuation force is concentrated on a small central region of the brake liner, leading to uneven wear and reduced brake power.
Innovation Solution
A force transmission apparatus with a pressure element that distributes the actuation force via spaced-apart contact regions, incorporating recessed regions and reinforcement webs to direct force to eccentric areas of the brake liner, optimizing force distribution and reducing weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the actuation force is applied through a small cross-sectional area at the center of the brake liner, then the brake system can be compact and simple, but the force distribution becomes uneven causing central concentration and reduced brake power
Solution Approach 1:
The pressure plate is segmented into multiple contact regions (first contact region, second contact region, third contact region) that are spatially distributed across the brake liner surface. This segmentation allows the actuation force to be divided and applied at multiple locations simultaneously, preventing central concentration and achieving more uniform force distribution across the brake liner.
Solution Approach 2:
Different regions of the pressure plate are designed with different contact characteristics. The first contact region has a first contact area, the second contact region has a second contact area, and the third contact region has a third contact area. These local variations in contact quality allow optimized force distribution tailored to specific regions of the brake liner, improving overall brake power while maintaining uniformity.
2Ease of operation
If a pressure plate is used to distribute force across the brake liner, then force distribution improves, but the device complexity increases due to additional components
Solution Approach 1:
The pressure plate integrates multiple contact regions (first, second, and third contact regions) into a single component that directly interfaces with the brake liner. By merging these contact regions into one integrated pressure plate rather than using separate components, the design achieves uniform force distribution while minimizing device complexity.
Solution Approach 2:
The pressure plate serves multiple functions simultaneously: it distributes force uniformly across the brake liner, maintains contact at multiple regions, and acts as a structural element connecting the actuation mechanism to the brake liner. This multi-functionality reduces the need for additional components, thereby reducing overall device complexity.
3Ease of manufacture
If the pressure element has uniform thickness throughout, then manufacturing is simpler, but weight cannot be optimized and force distribution to outer regions is limited
Solution Approach 1:
The pressure element features variable thickness with different thickness regions: a first thickness region, a second thickness region, and a third thickness region. This local variation in thickness allows optimization of weight by reducing material in non-critical areas while maintaining sufficient thickness for force transmission in critical contact regions. The different thicknesses also help direct force toward outer regions of the brake liner.
Solution Approach 2:
The thickness parameter of the pressure element is changed across different regions rather than maintaining a constant value. By varying the thickness parameter locally, the design achieves weight optimization and improved force distribution to outer brake liner regions while remaining manufacturable through standard forming processes.
Data Source
AI summary
The present disclosure relates to a force transmission apparatus for a disc brake, The apparatus comprises an actuation element, a brake liner arrangement having a brake liner and a carrier plate, and a pressure element. The pressure element has a thickness which extends toward the actuation direction, a length extending in a tangential direction of an associated brake disc in an installed state and a width which extends in a radial direction of an associated brake disc in the installed state. The pressure element has a force input side operationally connected to the actuation element and a force output side. The force output side has contact regions spaced apart from each other and operationally connected to the carrier plate. The force output side has a region which is recessed into the pressure element. The recessed region has a first reinforcement web which connects the contact regions to each other such that the first reinforcement web is not recessed or is recessed less than the recessed region.