Disc Brake Reset Device With Segmented Elastic And Plastic Deformation

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Solution Overview

Problem

Disc brakes with combined elastic and plastic deformation regions face impairment in reset functionality due to heavy wear, leading to inadequate brake pad compensation.

Innovation Solution

A disc brake design where the plastically deformable region is only deformable after the elastically deformable region has reached a predetermined elastic deformation, with a loop-shaped plastically deformable region that rolls out along the guide surface for wear compensation, allowing for separate adjustment of reset and wear compensation forces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If one and the same region serves both as elastically deformable region for resetting and as plastically deformable region for wear compensation, then the device complexity is reduced, but the reliability deteriorates due to impairment of reset functionality under heavy wear

Engineering Contradiction:

Improvestructure complexityVSAvoidreset functionality

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The reset device is divided into two distinct functional regions: an elastically deformable region (33) dedicated to resetting the brake pad assembly, and a plastically deformable region (37) dedicated to wear compensation. This segmentation ensures that each region performs its specific function independently without interfering with the other, thereby maintaining high reliability while managing device complexity through functional specialization.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If the plastically deformable region is designed to roll out along the guide surface for wear compensation, then the adaptability to wear is improved, but the manufacturing precision requirements increase

Engineering Contradiction:

Improvewear compensation capabilityVSAvoiddeformation path control

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

A guide surface (F) is introduced as an intermediary element between the plastically deformable region (37) and the retaining tongue (12). This guide surface controls and directs the plastic deformation process, ensuring that the deformable region rolls out along a predetermined path. The guide surface mediates the interaction, allowing adaptability to wear while managing manufacturing precision requirements by providing a controlled deformation pathway.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If the elastically deformable region is designed to provide predetermined exclusive elastic deformation, then the reset properties are maintained, but the device complexity increases due to separate adjustment mechanisms

Engineering Contradiction:

Improvereset propertiesVSAvoidadjustment mechanism

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The elastically deformable region (33) is designed with specific local properties: it is configured to provide predetermined exclusive elastic deformation along a defined path. The local quality of this region is optimized for reset functionality, with controlled deformation characteristics that maintain reliable reset properties. The separation of this region from the plastic deformation region allows independent optimization of each function.

Inventive Principle:

Principle #3Local quality

4Ease of operation

If the plastically deformable region is formed as a loop that can roll out, then the ease of operation for wear compensation is improved, but the manufacturing complexity increases

Engineering Contradiction:

Improvewear adaptationVSAvoidloop structure fabrication

Core Design Contradiction:

Ease of operationVSEase of manufacture

Solution Approach 1:

The plastically deformable region (37) is formed as a loop structure with curved geometry that can roll out along the guide surface. This curved configuration facilitates ease of operation for wear compensation by enabling smooth plastic deformation through rolling motion. The loop shape provides mechanical advantage for wear adaptation while the curvature is designed to accommodate manufacturing processes.

Inventive Principle:

Principle #14Spheroidality (Curvature)

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 design ensures that wear compensation does not affect reset properties, allowing for precise wear limit determination and preventing excessive brake pad wear, thus maintaining optimal braking performance.

Implementation Method 1

a reset device, via which reset device a reset force acting opposite to the actuation direction as a result of an elastic deformation due to braking deflection of the brake pad assembly can be applied to this

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Implementation Method 2

a following plastically deformable region for permanent adaptation to wear of the vehicle brake pad

Methodology Applied

Scientific EffectPlastic deformation: Plasticity

Data Source

PatentUS10663021B2Disc brake for a motor vehicle and brake pad assembly therefor

Publication Date: 2020.05.26 ZF ACTIVE SAFETY GMBH

AI summary

A disc brake for a motor vehicle having a reset device that can only be plastically deformed, as a result of a force acting thereon in the actuation direction along a guide surface of the receiving region, if the reset device has adopted a predetermined, exclusively elastic deformation as a result of this force, wherein the plastically deformable region is formed as a loop and is in direct contact with the retaining tongue and can also roll out along the guide surface during the plastic deformation.