Sheet-Steel Bow Spring for Simpler Disc Brake Pad Retention
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Solution Overview
Problem
Existing disc brake clearance spring systems are not maintenance-friendly and production-efficient, often requiring additional fixations and interfaces that complicate assembly and increase costs.
Innovation Solution
A compact, one-piece sheet steel bow spring design with U-shaped spring legs and friction lining retaining clips that clamp the friction lining back plates, eliminating the need for separate fixations and allowing for pre-assembly as a wear parts kit, while maintaining a compact and aerodynamic shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate fixations and additional interfaces are used for friction lining retention, then the friction lining can be securely fixed, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the friction lining retention function directly into the air spring structure by forming retaining clips at the ends of the spring legs. This integration eliminates the need for separate fixation components and additional interfaces, reducing device complexity while maintaining secure friction lining retention through the clamping action of the integrated clips
2Reliability
If multiple separate components are used for the clearance spring system, then the spring can be securely mounted, but the ease of manufacture and assembly deteriorate
Solution Approach 1:
The patent merges multiple functions into a single one-piece air spring component that includes spring legs, retaining clips, and mounting interfaces all formed as one integrated structure. This eliminates the need for assembling multiple separate components, significantly improving ease of manufacture and assembly while maintaining secure mounting through the integrated design
Solution Approach 2:
The air spring is designed with distinct functional segments (spring legs for elasticity, retaining clips for friction lining fixation, yoke section for mounting) that are integrated into one piece. This segmentation of functions within a unified structure allows for optimized performance of each function while maintaining manufacturing simplicity
3Ease of manufacture
If a compact one-piece design is used, then the space efficiency and manufacturing cost improve, but the friction lining retention capability may worsen
Solution Approach 1:
The patent successfully combines the friction lining retention function within the one-piece air spring structure by forming retaining clips at the spring leg ends. These integrated clips provide effective clamping capability on the friction lining backplate, ensuring reliable retention while maintaining the manufacturing advantages of a single-component design
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 enables a maintenance-friendly, cost-effective, and space-efficient disc brake design that reduces noise and assembly confusion, allowing for easy replacement and integration with existing brake systems without compromising performance.
Implementation Method 1
the spring legs are essentially U-shaped and plastically offset from each other, forming elastic spring arms
Data Source
Figure 1~2
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AI summary
The invention relates to a fixed-caliper sectioned-brake-pad disc brake (1) for motor vehicles, with pin-type mounting for backing plates (7) of disc brake pads (2, 3), comprising a one-piece clearance spring (20, 21) having two spring legs (22, 23), which is elastically clamped between the backing plates (7) at a part of the mounting that has no friction material. The object of the invention is to provide a novel brake having a clearance spring system or an alternative more flexibly adjustable floating clearance spring system for a fixed-caliper sectioned-brake-pad disc brake for motor vehicles, which allows even more maintenance-friendly and production-oriented interface design. The object is achieved in that the clearance spring (20, 21) is a steel bow spring having a yoke section (24) which extends over the disc brake pads (2, 3), and having spring legs (22, 23) which are plastically bent parallel to one another away from the yoke section (24) in a substantially U-shaped form, and which elastically resiliently engage behind the friction lining backing plates (7) at a part of the mounting that has no friction material.