Floating-Caliper Disc Brake Asymmetric Lining
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Solution Overview
Problem
Existing floating-caliper disc brakes require frequent adjustments and replacements due to wear, leading to increased displacement travel of the brake caliper, which occupies valuable installation space.
Innovation Solution
The brake caliper's displacement travel is reduced by making the friction lining thickness of the reaction-side pad less than that of the application-side pad, allowing for unequal thickness while maintaining equal volume, and adjusting the brake disc's friction ring thickness to match, thereby reducing the wear adjustment travel and optimizing installation space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the friction lining thickness of both brake pads is made equal (symmetric design), then the brake disc friction ring thickness can be optimized, but the brake caliper displacement travel becomes large requiring more installation space
Solution Approach 1:
The patent applies asymmetry by making the friction lining thickness of the reaction-side brake pad different from that of the application-side brake pad. Specifically, the reaction-side friction lining thickness is reduced while maintaining equal volume through increased width, thereby reducing the brake caliper displacement travel and optimizing installation space without compromising braking performance
Solution Approach 2:
The patent applies local quality by differentiating the friction lining characteristics at different locations of the brake pad. The reaction-side brake pad has different thickness and width dimensions compared to the application-side pad, with each dimension optimized for its specific functional requirements - the reaction-side pad has reduced thickness but increased width to maintain volume while reducing caliper travel
2Area of stationary object
If the brake caliper displacement travel is reduced, then installation space is optimized, but the friction lining thickness configuration becomes asymmetric
Solution Approach 1:
The patent resolves this contradiction by intentionally introducing asymmetry in the friction lining thickness configuration. The reaction-side brake pad has a different thickness profile compared to the application-side pad, which directly enables reduced brake caliper displacement travel and optimized installation space while maintaining overall system balance through volume equivalence
3Quantity of substance
If the friction lining volume is maintained equal for both pads, then material usage is optimized, but the friction lining thickness must be increased on one side reducing caliper travel
Solution Approach 1:
The patent applies parameter changes by modifying the thickness and width parameters of the friction lining on the reaction-side brake pad. By reducing the thickness parameter while increasing the width parameter to maintain constant volume, the patent achieves reduced brake caliper displacement travel without changing the total quantity of friction material
Solution Approach 2:
The patent uses asymmetry to distribute the friction lining volume differently between the two brake pads. The reaction-side pad has reduced thickness but increased width compared to the application-side pad, creating an asymmetric configuration that reduces caliper travel while preserving total friction material volume
Data Source
AI summary
A floating-caliper disc brake of a utility vehicle includes a brake disc, a brake carrier spanning the brake disc and having lining shafts arranged on both sides of the brake disc, a brake caliper overlapping the brake disc and movable relative to the brake carrier, brake linings arranged on both sides of the brake disc in a lining shaft of the brake carrier, and having a lining carrier plate and a friction lining attached thereto. An application-side brake lining can be pressed against the brake disc by an application device and a reaction-side brake lining can be pressed against the brake disc by a brake caliper back, by moving the brake caliper. The brake caliper can be reset by a resetting device along a wear adjustment path in an axial direction to the axis of rotation of the brake disc. With the same volume of the friction linings in the new condition, the friction lining thickness of the reaction-side brake lining is not the same as the friction lining thickness of the application-side brake lining (5).