Disk Brake Guide Element Structure for Secure Low-Mass Attachment

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Solution Overview

Problem

Existing guide elements for disk brake systems are not space-saving, material-saving, and weight-saving, and their attachment to brake anchors is not straightforward, leading to inefficiencies in braking operations.

Innovation Solution

A guide element with a fixing portion extending transversely and a connecting portion that spans the axial direction, allowing for precise alignment and secure attachment to the brake anchor, while minimizing material and weight usage, and featuring an elastically deformable spring portion for enhanced stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If traditional guide elements are used for disk brake systems, then the braking function is achieved, but the guide elements are not space-saving, material-saving, and weight-saving

Engineering Contradiction:

Improveguide element volumeVSAvoidguidance reliability

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The guide element is divided into three distinct functional portions: a guide portion (5) that engages with the guide groove and guide projection, a connecting portion (11) that provides structural support and force transmission, and a fixing portion (9) that attaches to the brake anchor. This segmentation allows each portion to be optimized for its specific function while minimizing overall material usage and volume.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The connecting portion extends in a second extent direction that is transverse to both the axial direction and the first extent direction, creating a three-dimensional configuration. This spatial arrangement allows the guide element to achieve stable attachment and guidance functionality with minimal material, as the connecting portion bridges the guide and fixing portions through an efficient geometric path.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Ease of manufacture

If traditional guide elements are used, then the braking operation is maintained, but the attachment to brake anchor is not straightforward

Engineering Contradiction:

Improveattachment easeVSAvoidguide element structure

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The guide element utilizes the existing guide groove in the brake anchor and guide projection on the brake pad arrangement to automatically position and align itself during installation. The fixing portion can be directly attached to the brake anchor without requiring additional alignment fixtures or complex assembly procedures, as the guide portion self-aligns through the existing guide structures.

Inventive Principle:

Principle #25Self-service

3Reliability

If more material is used to improve stability, then attachment reliability is enhanced, but weight and material consumption increase

Engineering Contradiction:

Improveattachment reliabilityVSAvoidguide element weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

Different portions of the guide element have different structural characteristics optimized for their specific functions: the guide portion has a U-shaped cross-section for engagement, the connecting portion has an L-shaped configuration for efficient force transmission, and the fixing portion has a plate-like structure for secure attachment. This local optimization ensures adequate strength and reliability in each region without excessive material usage throughout the entire component.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The guide element can be manufactured as a single-piece component from elastic metal material, combining the properties of metallic strength with elastic deformability. This allows the thin-walled, lightweight structure to maintain high attachment reliability through elastic recovery and stress distribution, rather than requiring thicker walls or additional material.

Inventive Principle:

Principle #40Composite materials

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 guide element ensures precise guidance and secure attachment to the brake anchor, reducing noise and improving braking efficiency with a space-saving, material-saving, and weight-saving design that facilitates easy attachment and stable operation.

Implementation Method 1

The guide element (1) has a elastically deformable spring portion (13)

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS20230160445A1Guide element and brake anchor for a disk brake system, and disk brake system

Publication Date: 2023.05.25 ZF ACTIVE SAFETY GMBH

AI summary

The disclosure illustrates and describes a guide element which extends from a first end via a guide portion to a second end. The guide element has a fixing portion arranged at the second end and extending along a first extent direction, which runs transversely with respect to the axial direction, to a free end. The guide element has a connecting portion between the guide portion and the fixing portion. The connecting portion extends along a second extent direction, which runs transversely with respect to the axial direction and transversely with respect to the second extent direction, and extends along the axial direction from a first plane, which runs perpendicular to the axial direction, to a second plane, which runs perpendicular to the axial direction. The fixing portion is spaced apart in an axial direction both from the first plane and from the second plane. The disclosure furthermore relates to a corresponding brake anchor and to a corresponding disk brake system.