Disc Brake Sheet Metal Ring Cutouts for Bellows Heat Shielding
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Solution Overview
Problem
Existing disc brake systems for commercial vehicles face challenges in effectively managing thermal radiation and contamination protection, particularly in modular construction where thermal insulation and flexibility are compromised by high flexural stiffness in sheet metal arrangements.
Innovation Solution
A sheet metal arrangement with a sheet metal ring featuring cutouts to reduce flexural stiffness, integrated with a central sheet metal plate and a heat-resistant, non-stick disc for enhanced thermal protection and flexibility, protecting the bellows against thermal radiation and contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a sheet metal ring is used to protect the bellows against thermal radiation, then thermal protection is improved, but flexural stiffness increases which compromises flexibility and elastic deformation capability
Solution Approach 1:
The sheet metal ring is segmented by introducing cutouts that divide the continuous ring structure into separated sections. This segmentation reduces the overall flexural stiffness while maintaining the thermal protection function, allowing the ring to deform elastically under thermal expansion or mechanical loads without compromising its ability to shield the bellows from thermal radiation.
Solution Approach 2:
The cutouts are strategically positioned in specific locations of the sheet metal ring to create localized flexibility zones. These local modifications reduce flexural stiffness precisely where needed while preserving the thermal barrier function in critical areas, enabling the structure to adapt to thermal and mechanical stresses.
2Stability of the object's composition
If a sheet metal arrangement is used for structural support, then structural integrity is improved, but adaptability to thermal expansion and deformation is worsened
Solution Approach 1:
The sheet metal ring transitions from a static, rigid structure to a dynamic, adaptable component through the introduction of cutouts. These cutouts enable the ring to undergo elastic deformation and adapt to thermal expansion, compression, or other mechanical stresses while maintaining overall structural integrity and continuing to fulfill its protective function.
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
The reduced flexural stiffness allows for improved elastic deformation and targeted thermal insulation, effectively protecting the bellows from thermal radiation and contamination, while maintaining structural integrity and preventing adhesion, thus enhancing the overall performance of the disc brake system.
Implementation Method 1
the sheet metal ring is disposed between the bellows and the brake pad for protecting the bellows against thermal radiation that is generated on the brake pads and the brake disc by braking procedures
Implementation Method 2
the sheet metal ring, for reducing the flexural stiffness thereof, has at least one cutout
Data Source
AI summary
A disc brake for a vehicle, having a first and a second brake lining (2a), and a brake disc (1) which is arranged between them, and a brake caliper which engages over the brake disc (1) with a brake caliper housing (6), in which a brake application device is arranged, wherein the brake application device comprises a pressure piece (3) which can be applied against the first brake lining (2a), wherein a boot (5) is provided for protecting the interior of the brake caliper housing against contaminants, wherein the boot (5) is fastened by way of a first end region (5a) to the brake caliper housing (6) and by way of a second end region (5b) to a sheet metal arrangement (7) consisting of a sheet metal plate (8) and a sheet metal ring (9) which is arranged coaxially with respect thereto and is connected in an integrally joined manner to said sheet metal plate (8), wherein the sheet metal plate (8) is arranged between an end side of the pressure piece (3) and the first brake lining (2a), wherein the sheet metal ring (9) is arranged between the boot (5) and the brake lining (2a) for protecting the boot (5) against heat radiation which is generated by way of braking operations on the brake linings (2a, 2b) and the brake disc (1), and wherein the sheet metal ring (9) has at least one cut-out (11) for reducing its flexural stiffness.