Brake Caliper Band Spring Assembly for Stable Pad Retraction
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Solution Overview
Problem
Existing disc brake spring systems require complex assembly and are prone to connection issues under external stresses, lacking a secure and durable connection to the caliper body without central connection bridges, and struggle to maintain the spring-pad contact point position under external biases.
Innovation Solution
A band spring design with three constraint zones that connects to the caliper body via side bridges, utilizing geometric features to maximize friction forces and minimize sliding forces, ensuring a secure and durable attachment and maintaining the spring-pad contact point position despite external forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a pair of springs is used to move the brake pad away from the brake disc in a balanced manner, then the reliability of pad separation is improved, but the device complexity and assembly time increase
Solution Approach 1:
The single spring is divided into two functional halves by the central bridge, with each half acting as an independent connection element. This segmentation allows the spring to function similarly to a pair of springs (providing balanced pad separation) while actually being a single integrated component, thus reducing assembly complexity while maintaining reliability
Solution Approach 2:
The invention merges the functions of two separate springs into a single spring structure. The central bridge serves as a shared connection point that integrates the two spring halves, combining the benefits of balanced pad separation (normally requiring two springs) with the simplicity of a single component design
2Ease of manufacture
If the spring is connected to a central connection bridge made by casting, then the ease of manufacture is improved, but the reliability of connection under high external stresses deteriorates
Solution Approach 1:
The invention extracts the spring connection from the central connection bridge and relocates it to the side connection bridges. This removes the vulnerable casting connection from the high-stress spring mounting location, while the side bridges provide more reliable attachment points that can better withstand external stresses
Solution Approach 2:
The side connection bridges serve as intermediary structures that mediate between the spring and the caliper body. These bridges provide a more reliable connection interface than the central bridge, acting as a mediator that transfers spring forces more effectively while maintaining connection integrity under stress
3Device complexity
If the spring abuts against the apical portion of the pads, then the simplicity of the spring design is improved, but the stability of the spring-pad contact point position deteriorates under external forces
Solution Approach 1:
The invention changes the dimension of contact by extending the spring abutment from a single apical point contact to a distributed contact along the pad surface. This dimensional change from point contact to surface contact provides stability against external forces while maintaining relatively simple spring 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 band spring design facilitates a simple, secure, and durable connection to the caliper body, maintaining the spring-pad assembly's functionality and preventing position changes under external biases, while ensuring progressive wear and minimizing operational interference.
Implementation Method 1
a band spring (1) adapted to apply an elastic action on at least one brake pad (3) to bias it away from said brake disc (2)
Implementation Method 2
utilizing geometric features to maximize friction forces and minimize sliding forces, ensuring a secure and durable attachment and maintaining the spring-pad contact point position despite external forces
Data Source
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AI summary
The present invention relates to a spring (1) for a caliper body (8), wherein said spring (1) is shaped to be arranged straddling a brake disc (2) for applying an elastic action on at least one brake pad (3) to bias it away from said brake disc (2); wherein - said brake disc (2) is adapted to rotate about a rotation axis (X-X), which defines an axial direction (A-A), parallel to said rotation axis (X-X), a radial direction (R-R), orthogonal to said rotation axis (X-X), and a tangential direction (T-T) orthogonal both to said axial direction (A-A) and to said radial direction (R-R) ; - said caliper body (8) comprising a first elongated element or wheel side elongated element (38), a second elongated element or opposite wheel side elongated element (39), a first side bridge (40) and a second side bridge (41) adapted to connect said first elongated element (38) to said second elongated element (39) straddling said brake disc (2) and leaving a central portion of said caliper body (8) free from a central connection bridge, said spring (1) comprising: - a first thrust portion (5) and a second thrust portion (6) adapted to apply said elastic action on said at least one brake pad (3), biasing said brake pad (3) at least away from said brake disc (2) in the axial direction (A-A) and the radial direction (R-R); - a first coupling portion (14) adapted to couple said spring with said first side bridge (40); - a second coupling portion (15) adapted to couple said spring (1) with said second side bridge (41) on a tangentially opposite part with respect to said first coupling portion (14), - a backing portion (7) adapted to abut against a caliper pin (16) planted in said caliper body (8) or a caliper tie-rod (17) screwed to said caliper body (8) avoiding coupling with said caliper pin (16) or said caliper tie-rod (17), wherein said spring (1) comprises at least one concave spring portion (46) having a concavity facing towards said brake disc (2) so that at least said backing portion (7) is elastically movable in a radial direction (R-R) towards said brake disc (2) between a rest configuration and at least one work configuration, elastically stressing said first coupling portion (14) and said second coupling portion (15) along said tangential direction (T-T) in opposite directions.