Angled Brake Pad Spring Geometry for Low Drag Torque

Solution Overview

Problem

Existing disk brake systems face challenges in reducing undesired drag torque during driving, leading to issues like long pedal travel, increased noise/vibration/harshness (NVH), and temperature dependence, which affect braking performance.

Innovation Solution

A brake pad spring design featuring two opposing walls with a non-vanishing angle and diminishing distance from a non-braking to a braking position, providing an elastic return spring effect to guide brake pads between positions without the need for a retraction spring.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a retraction spring is used to push the brake pad back into the non-braking position, then the brake pad can be returned to initial position, but the device complexity increases and the reliability decreases due to fault-prone components

Engineering Contradiction:

Improvebrake pad retractionVSAvoidbrake pad spring structure

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The guiding function and the retraction spring function are merged into a single integrated brake pad spring structure. The opposing walls with non-vanishing angle simultaneously guide the brake pad movement and provide the elastic restoring force, eliminating the need for separate retraction springs.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The brake pad spring structure serves itself by using its own geometric configuration (opposing walls with non-vanishing angle) to generate the restoring force needed for brake pad retraction, without requiring additional dedicated components.

Inventive Principle:

Principle #25Self-service

2Ease of operation

If a retraction spring is used to guide the brake pad, then the brake pad can be pushed back, but the reliability decreases as the spring can break and assembly becomes difficult

Engineering Contradiction:

Improvebrake pad guidanceVSAvoidbrake pad spring durability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The guiding function and the retraction spring function are merged into a single integrated brake pad spring structure. The opposing walls with non-vanishing angle simultaneously guide the brake pad movement and provide the elastic restoring force, eliminating the need for separate retraction springs.

Inventive Principle:

Principle #5Merging (Combining)

3Productivity

If traditional brake pad springs are used, then brake pad guidance is provided, but drag torque during driving cannot be reduced to zero and NVH increases

Engineering Contradiction:

Improvebraking performanceVSAvoiddrag torque and NVH

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The geometric parameters of the brake pad spring are optimized, specifically the angle between opposing walls and the diminishing distance configuration, to minimize drag torque while maintaining effective brake pad guidance and retraction functionality.

Inventive Principle:

Principle #35Parameter changes

4Ease of operation

If brake pad springs with recessed portions are used to receive the backplate, then the brake pad can be guided, but long pedal travel is required

Engineering Contradiction:

Improvebrake pad positioningVSAvoidpedal travel

Core Design Contradiction:

Ease of operationVSLength of moving object

Solution Approach 1:

The geometric parameters of the brake pad spring are optimized, specifically the angle between opposing walls and the diminishing distance configuration, to minimize drag torque while maintaining effective brake pad guidance and retraction functionality.

Inventive Principle:

Principle #35Parameter changes

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 solution effectively reduces drag torque, improves pedal feel, and simplifies assembly by eliminating the need for a retraction spring, while maintaining consistent braking performance across various driving conditions.

Implementation Method 1

At least a portion of at least one of the two opposing walls is elastically movable. The two opposing walls, at least sectionally, have a non-vanishing angle with respect to each other, a distance between the two opposing walls diminishing from the first section towards the second section. This creates a return spring effect for the respective brake pad

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS12215748B2Brake pad spring and disk brake system

Publication Date: 2025.02.04 HL MANDO CORP

AI summary

The invention relates to a brake pad spring (1) for at least one brake pad (2), in particular for two brake pads, wherein the brake bad spring (1) comprises, for each of the at least one brake pad (2), two opposing walls (9, 10), configured for receiving a portion of a backplate (3) of the respective brake pad (2) therebetween, and for guiding the respective brake pad (2) between a non-braking position (A) in which the respective brake pad (2) is located at a first section (S1) of the opposing walls (9, 10), and a braking position (B) in which the brake pad (2) is located at a second section (S2) of the opposing walls (9, 10). At least a portion of at least one of the two opposing walls (9,10) is elastically movable and the two opposing walls (9, 10), at least sectionally, have a non-vanishing angle with respect to each other, a distance between the two opposing walls (9, 10) diminishing from the first section (S1) towards the second section (S2), in order to create a return spring effect for the respective brake pad (2), from the braking position (B) towards the non-braking position (A). The invention also relates to a disk brake system, comprising a brake disk (5) and a brake pad spring (1) which is mounted on a carrier (7).