Commercial Vehicle Disc Brake Pad Retention With Split Securing
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Solution Overview
Problem
Existing disk brake designs for utility vehicles, particularly sliding caliper brakes, face challenges in securely holding brake pads in place during braking, leading to potential misalignment and increased wear, which complicates the pad replacement process and requires additional securing systems.
Innovation Solution
A disk brake design featuring a brake caliper with a central opening for easy pad insertion and a hold-down clip that radially secures only the reaction-side brake pad, while the application-side pad is secured through a form fit, reducing material usage and simplifying the mounting process by eliminating the need for additional securing mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a hold-down clip is used to secure brake pads radially, then the brake pads are held securely in place, but the structure becomes more complex and material usage increases
Solution Approach 1:
The brake pad securing system is segmented into two distinct methods: the application-side brake pad uses form-fit engagement with the brake carrier, while the reaction-side brake pad uses a hold-down clip. This segmentation allows each side to use the most appropriate securing method for its specific functional requirements, reducing overall system complexity while maintaining reliability.
Solution Approach 2:
Instead of using hold-down clips on both brake pads, the invention applies the hold-down clip only partially - specifically on the reaction-side brake pad where it is most needed. The application-side brake pad relies on form-fit engagement, which is sufficient for its role. This partial application reduces structural complexity and material usage while maintaining adequate securing for both pads.
2Reliability
If additional securing mechanisms are added to hold brake pads, then braking reliability improves, but manufacturing complexity and cost increase
Solution Approach 1:
The manufacturing process is simplified by segmenting the brake pad assembly into two distinct attachment methods. The application-side brake pad uses a simple form-fit engagement that requires minimal manufacturing steps, while the reaction-side brake pad uses a hold-down clip that can be easily attached. This segmentation allows each component to be manufactured and assembled independently, reducing overall manufacturing complexity.
Solution Approach 2:
Instead of using a complex unified securing mechanism for both brake pads, the invention inverts the approach by using simple form-fit engagement for the application-side pad and adding a hold-down clip only where necessary for the reaction-side pad. This inversion from a complex unified system to a simplified segmented system reduces manufacturing complexity while maintaining braking reliability.
3Reliability
If brake pads are securely held in place, then oblique wear is reduced, but the pad replacement process becomes more complex
Solution Approach 1:
The brake pad assembly is segmented into two types with different securing methods, allowing the application-side brake pad to be easily replaced through simple form-fit engagement while the reaction-side brake pad uses a hold-down clip for secure mounting. This segmentation enables differentiated replacement procedures that balance ease of operation with wear resistance requirements.
Solution Approach 2:
The hold-down clip is extracted as a separate, removable component from the brake pad assembly. This allows the clip to be easily removed and reattached during pad replacement, maintaining secure holding during operation while simplifying the replacement process. The clip can be quickly detached without requiring complex tools or procedures.
Data Source
AI summary
A disc brake for a commercial vehicle is provided. The disc brake includes a brake caliper, preferably in the form of a sliding caliper, straddling a brake disc, being arranged on a fixed backing plate, and having an application device for applying the brake. The disk brake also includes two brake pads, each having a pad carrier and an affixed friction pad, and each being inserted into a pad shaft of the backing plate. The brake caliper has a central caliper opening over the disc brake. A hold-down bar is provided, designed in such a way that, of the two brake pads, it radially secures only the reaction-side brake pad in its lining shaft in the backing plate. The hold-down bar is held on the brake caliper by its end facing away from the brake pad. Additionally, the application-side brake pad is radially interlockingly secured in its pad shaft in the backing plate. The application-side brake pad has a brake pad spring, which is held on the application-side brake pad and includes ends which rest resiliently on horns of the backing plate.