Disc Brake Pad Retention via Spring-Loaded Caliper Integration
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Solution Overview
Problem
Existing disc brake systems for commercial vehicles face high production costs, rattling noises during operation, and reduced operational reliability due to the use of pad retaining clips, which require costly machining and can lead to corrosion.
Innovation Solution
The disc brake design eliminates the need for a pad retaining clip by directly supporting the brake pads with a spring-loaded pad retaining spring on the underside of the brake caliper, allowing for controlled spring force adjustment and reduced wear, and features a two-part spring design for easy assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a pad retaining clip is used to secure brake pads, then the brake pads can be held in position, but manufacturing costs increase due to material procurement and machining of the brake caliper
Solution Approach 1:
The invention extracts and eliminates the pad retaining clip from the brake system by integrating the retaining function directly into the brake caliper structure. The brake caliper is designed with recesses that directly receive and hold the brake pads, removing the need for separate retaining clips and their associated fastening elements.
Solution Approach 2:
The retaining function is merged with the brake caliper structure itself. The caliper body incorporates recesses that serve both as mounting features and as retaining structures, combining multiple functions into a single integrated component.
2Reliability
If a pad retaining clip is used to secure brake pads, then the brake pads can be held in position, but machining of the brake caliper increases costs due to introduction of fastening elements
Solution Approach 1:
The invention removes the need for separate fastening elements by integrating the retaining function into the caliper's structural design. The recesses in the caliper body provide inherent retention without requiring additional fastening components or complex machining operations.
3Reliability
If a pad retaining clip is used to secure brake pads, then the brake pads can be held in position, but rattling noises occur during operation due to brake pads hitting during vibrations
Solution Approach 1:
The invention merges the brake pad retention function with the caliper structure, creating a continuous, integrated connection that eliminates gaps and movement between components. This integration prevents the relative motion and impact that generate rattling noises during vehicle vibration.
4Force
If the brake pad is held by the pad retaining spring in conjunction with the brake caliper, then holding forces can be increased, but the spring force must be precisely controlled to reduce residual drag torque
Solution Approach 1:
The invention controls the spring force parameters to optimize performance. The pad retaining spring is designed with specific mechanical properties and pre-load characteristics that provide high holding forces while minimizing residual drag torque through careful parameter selection and adjustment.
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 significantly reduces manufacturing costs, eliminates rattling noises, enhances operational reliability, and allows for higher holding forces and reduced residual drag torque, improving the overall performance and cost-effectiveness of the disc brake.
Implementation Method 1
Each brake pad is held in a pad shaft of a stationary brake carrier by means of a pad retaining spring, which is fastened to the brake pad in a spring-loaded manner
Data Source
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AI summary
The brake has brake linings (2) arranged on both sides of a brake disk. The brake linings are held in a lining groove (10) of a fixed brake bracket (6) or a brake caliper (1) by a associated lining retaining spring (4) e.g. leaf springs, in a spring-loaded manner. The lining retaining spring is supported at a side of an end at a wall-inner side of the brake caliper, where the inner side is turned to the brake disk. Two parts of the lining retaining springs are fixedly connected with each other by a connecting element after mounting the brake linings.