Utility Vehicle Disk Brake Closure Plate Bonding
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Solution Overview
Problem
Existing disc brake designs for commercial vehicles face challenges in weight optimization, as the closure plate is dimensioned to absorb functional loads, leading to high weight and increased production costs due to time-consuming and costly screw-based attachment methods, which also pose risks to operational reliability and security.
Innovation Solution
An integral connection of the closure plate to the brake caliper via gluing, eliminating the need for screws and threaded holes, combined with a reinforcing element for the closure plate's contact area with the compression spring, allowing for a thinner closure plate and reduced material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the closure plate is made thicker to withstand operational loads, then the strength and stability are improved, but the weight increases
Solution Approach 1:
The patent applies local reinforcement by providing reinforcing elements (such as ribs or thicker sections) only in specific high-stress areas of the closure plate, such as where the compression spring contacts the plate or around mounting openings. This allows the plate to withstand operational loads with adequate strength while keeping the overall thickness and weight reduced compared to a uniformly thick plate design.
2Reliability
If the closure plate is attached by screws, then the reliability of connection is improved, but the manufacturing time and cost increase
Solution Approach 1:
The patent merges multiple functions into the closure plate itself. The closure plate is designed with integrated mounting features (such as molded-in attachment points, clips, or interference-fit structures) that eliminate the need for separate screw fasteners. This integration maintains reliable connection while significantly reducing manufacturing steps, assembly time, and cost.
Solution Approach 2:
The patent replaces the mechanical screw-fastening system with an alternative attachment mechanism such as adhesive bonding, snap-fits, or integral forming. This substitution eliminates the need for threaded holes, torque control, and screw tightening operations, thereby improving manufacturing efficiency while maintaining adequate connection reliability for the application.
3Weight of moving object
If the closure plate is made thinner for weight optimization, then the weight is reduced, but the ability to withstand compression spring loads decreases
Solution Approach 1:
The patent addresses this contradiction by implementing local reinforcement strategies. Reinforcing ribs, gussets, or thicker plate sections are strategically placed in areas subjected to high compression spring loads, such as the central region or contact zones. This allows the overall plate thickness to be reduced for weight savings while maintaining adequate load-bearing capacity at critical locations.
Solution Approach 2:
The patent may utilize composite material structures or material with enhanced mechanical properties to achieve higher strength-to-weight ratio. By selecting materials or composite constructions that provide superior specific strength, the closure plate can be made thinner while still withstanding the compression spring loads effectively.
4Strength
If screws are used to fasten the closure plate, then the connection strength is improved, but the risk of unauthorized access and manipulation increases
Solution Approach 1:
The patent integrates the fastening function directly into the closure plate structure through molded-in attachment features, clips, or interference-fit designs. This integration eliminates removable screw fasteners that could be easily accessed and manipulated, thereby improving security against unauthorized access while maintaining adequate fastening strength through the integrated connection mechanism.
Solution Approach 2:
The patent extracts or eliminates the separate screw fastener component from the assembly. By removing the external screw element and replacing it with an integrated attachment system, the design eliminates the vulnerability point where screws could be accessed, loosened, or removed to gain unauthorized access to the receiving chamber.
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 enhances operational safety, reduces production costs, and achieves weight savings while maintaining structural integrity and sealing functionality, addressing the need for simpler, cost-effective, and secure disc brake production.
Implementation Method 1
the closure plate (4) is bonded to the brake caliper (1), in this example by adhesive bonding
Implementation Method 2
supporting a compression spring that returns the crossmember in the receiving chamber to its initial position when the brake is released
Implementation Method 3
a sealant, for example in the form of a circumferential sealing cord, is provided between the sealing plate and a contact surface surrounding the mounting opening of the brake caliper, which is squeezed when the sealing plate is attached in such a way that an overall tight seal is achieved
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a disk brake for a utility vehicle, comprising a brake caliper (1) which comprises a receiving chamber (2) for an application device, which is closed in a sealing manner when placed on the closure plate (4). Said application device comprises a traverse which can be moved with respect to the closure plate (4) and which is stressed by means of a brake lever and a compression spring (6), in which at least one brake piston, which traverses a through-opening (7) of the closure plate (4), is mounted, a bellows (3) being maintained by the end region thereof, sealing the through opening (7) on the edge thereof, also being connected to the brake piston. Said brake piston is designed such that the closure plate (4) is connected in a material fit to the brake caliper (1) and comprises a reinforcement element (10) at least in the bearing region of the compression spring (6).