Disk Brake Pad Support Geometry to Prevent Pad Unscrewing
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Solution Overview
Problem
Existing disc brakes in commercial vehicles face issues with the brake pad being unscrewed or falling out due to limited lateral support and the need for complex tooling for machining, which complicates processing and assembly.
Innovation Solution
The design features a U-shaped shaft with a smaller distance between the legs at the radially outer ends and a curved or angled bottom, allowing for secure radial support and simplified machining without the need for specialized tools, along with a hold-down device and adjusting mechanism for wear compensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the shaft is rectangular with equal distance between legs at radially outer and inner ends, then machining is simplified and brake pad assembly/disassembly is facilitated, but the brake pad cannot be reliably retained against falling out or unscrewing
Solution Approach 1:
The shaft is designed with asymmetric leg spacing where the distance between legs at the radially outer ends is smaller than at the radially inner ends. This asymmetric configuration creates a mechanical interference fit that prevents the brake pad from falling out or unscrewing during operation, while still allowing for relatively simple machining processes.
2Volume of moving object
If the lateral support horns are limited in radial extension, then space availability is optimized, but the brake pad cannot be reliably prevented from rotating out during braking
Solution Approach 1:
The asymmetric shaft geometry with converging legs creates a tapered configuration that provides increasing lateral support toward the radially outer region. This compensates for the limited radial extension of support horns by using the shaft's own geometry to prevent pad rotation out during braking.
3Ease of manufacture
If the bottom of the U-shaped shaft is flat, then machining is simplified using face mill or hob cutter, but the brake pad retention and stability are reduced
Solution Approach 1:
The bottom of the U-shaped shaft is designed with a curved or rounded configuration rather than a flat surface. This curvature enhances brake pad retention and stability by creating a more secure fit, while still being manufacturable with standard machining operations.
Data Source
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AI summary
A disk brake, in particular for utility vehicles, having a brake disk, having a brake caliper which engages over the brake disk, having a brake carrier (14), having a brake pad (16) and having a brake-application device which presses the brake pad against the brake disk during braking operations, wherein the brake pad is situated in a U-shaped slot, and the two legs of the "U" serve for supporting the brake pad in the circumferential direction of the brake disk and the "base" (32, 34) of the "U" serves for supporting the brake pad in a radially inward direction, wherein the spacing (B1) between the two legs of the "U" at the radially outer ends thereof is smaller than the spacing (B2) at the radially inner ends thereof.