Perforated Disc Brake Pressure Plate Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing disc brake systems for heavy-duty commercial vehicles require significant effort for assembly and disassembly, particularly when replacing wear and tear parts such as bellows seals, which are frequently needed.
Innovation Solution
A disc brake design featuring a perforated pressure plate that is axially secured to a pin on the pressure plunger, allowing for easy removal and featuring a longitudinal section for lateral guidance, along with alternative securing methods like retaining rings, press fits, or threaded connections, to reduce assembly and disassembly effort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the pressure plate is designed as a radially enlarged solid structure to increase contact area with the brake pad, then the compressive strength and force transmission are improved, but the assembly and disassembly effort increases significantly
Solution Approach 1:
The pressure plate is designed as a perforated disc with holes, segmenting the solid structure into a patterned configuration. This segmentation reduces the overall material volume and weight while maintaining structural integrity through the distributed hole pattern, allowing easier removal and installation without compromising the force transmission capability to the brake pad
2Area of stationary object
If the pressure plate is made solid and radially enlarged to improve force transmission, then the contact area with the brake pad is increased, but the replacement of wear parts becomes more complex
Solution Approach 1:
The perforated design segments the pressure plate structure, creating a lighter and more manageable component that can be easily removed and reinstalled. The hole pattern maintains sufficient structural integrity while reducing the overall mass and complexity of the component, facilitating straightforward replacement of wear parts such as seals
3Temperature
If the pressure plate is designed with large radial dimensions to increase contact area, then the heat dissipation capacity is improved, but the manufacturing complexity and material usage increase
Solution Approach 1:
The pressure plate employs a perforated disc design with distributed holes that create a porous-like structure. This configuration enhances heat dissipation capacity by increasing the surface area for thermal exchange while reducing material usage and manufacturing complexity compared to a solid radially enlarged structure. The hole pattern is optimized to maintain structural integrity while facilitating thermal management
Data Source
Figure 1~2c
Figure 3~4
Figure 5a~8
AI summary
The disk brake has a pressure plate (11) that is designed as a perforated disk. A hole (45) of the pressure plate is centrally arranged on a plunger (10). A pin (30) that faces a brake pad is locked axially with respect to the brake pad. A locking ring (40) locks the pressure plate axially in a complete or partial state. An end that faces a locking ring abutment surface (44) of the pressure plate is arranged in an annular groove (41) of the pin. A pressure surface (12) of the pressure plate is formed in a recess as compared to the locking ring abutment surface.