Bicycle Brake Pad Assembly With Integrated Spring and Barbed Pad Mounting
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Solution Overview
Problem
Existing bicycle brake pad assemblies often include separately formed brake pad backing plates, which add weight and complexity to the manufacturing process.
Innovation Solution
A one-piece spreader spring with integrated leaves and barbs secures friction pads directly to the rotor facing surfaces, eliminating the need for separate backing plates, and is formed by stamping and bending a sheet metal blank to create a lightweight and simplified assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If separately formed brake pad backing plates are used, then the structural strength and stability are improved, but the weight and manufacturing complexity increase
Solution Approach 1:
The patent combines the backing plate and spreader spring into a single integrated component formed from one piece of sheet metal. This merging eliminates the need for separate backing plates while maintaining the necessary structural strength through the interconnected design of the spring leaves and mounting features.
Solution Approach 2:
The integrated component serves multiple functions simultaneously: it acts as the backing plate for mounting friction pads, functions as the spreader spring to maintain pad separation, and provides mounting features for the friction pads. This multi-functionality reduces the number of parts and overall weight.
2Stability of the object's composition
If separately formed brake pad backing plates are used, then the structural stability is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent merges the backing plate and spreader spring into a single stamped component, reducing the number of parts that need to be manufactured, assembled, and quality-checked. This integration simplifies the manufacturing process while maintaining assembly stability through the inherent structural design.
Solution Approach 2:
While integrating components, the design maintains functional segmentation through the spring joint that divides the single piece into two leaves. This segmentation allows independent movement of each leaf while maintaining overall structural stability and simplifying the manufacturing of a single integrated piece.
3Weight of moving object
If a one-piece spreader spring is used, then the weight and manufacturing simplicity are improved, but the structural complexity increases
Solution Approach 1:
The one-piece spreader spring is segmented into two leaves joined at a central joint, allowing each leaf to function independently while maintaining overall structural integrity. This segmentation achieves weight reduction through integration while managing structural complexity through functional division.
Solution Approach 2:
The spring joint introduces dynamic flexibility to the otherwise rigid one-piece structure. This dynamic element allows the spring to flex and return to its original shape, providing the necessary mechanical function while maintaining manufacturing simplicity through a single-piece construction.
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 results in a lighter and easier-to-manufacture brake pad assembly that directly engages with the brake caliper, reducing manufacturing complexity and weight.
Implementation Method 1
The spreader spring is biased towards a spread position in which the first leaf and second leaf are spaced apart from each other
Implementation Method 2
The barbs of the first leaf are embedded in the first friction pad to secure the first friction pad to the first leaf. The barbs of the second leaf are embedded in the second friction pad to secure the second friction pad to the second leaf.
Data Source
AI summary
A brake pad assembly for a bicycle includes a spreader spring, and a pair of friction pads. The spreader spring has a first leaf, a second leaf, and a spring joint joining the first leaf and the second leaf together. The spreader spring is biased towards a spread position in which the first leaf and second leaf are spaced apart from each other, and is moveable to a compressed position in which the first leaf and the second leaf are moved towards each other relative to the spread position. Each leaf has a rotor facing surface, and each leaf has a set of grooves gouged into the rotor facing surface to yield a corresponding set of barbs extending from the rotor facing surface. The friction pads are secured to the rotor facing surfaces via the barbs, which are embedded in friction pads.