Brake Caliper Spring Assembly With Radial Winding for Low Residual Torque
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Solution Overview
Problem
Existing brake caliper spring assemblies face issues with high axial rigidity, plastic deformation during assembly, and limited versatility, leading to increased maintenance and production costs due to the need for specific designs for each application, while also failing to effectively reduce residual torque and vibration.
Innovation Solution
A pad-holding spring and pad return spring assembly with a compact, axially oriented wire spring design that uses a winding portion to store elastic energy, avoiding bends in the axial direction and allowing for easy assembly and modification, while maintaining high elastic return force and reducing the risk of deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the elastic return portion is bent with large envelope geometry in axial and radial directions, then the spring can provide elastic return force, but the axial rigidity becomes too significant generating large loads on the pad during wear
Solution Approach 1:
The patent reorients the elastic return portion from axial bending to radial bending. The elastic return portion now bends in a plane perpendicular to the axial direction (radial direction), changing the dimension of elastic deformation. This reduces axial rigidity while maintaining elastic return force, preventing excessive loads on the pad during wear.
2Reliability
If the pad return spring has large envelope in axial and radial directions, then the spring can function properly, but it causes envelope and weight gain negatively affecting vehicle performance
Solution Approach 1:
The patent repositions the elastic return portion to bend radially rather than axially. This dimensional change allows the spring to achieve proper function with reduced axial envelope, thereby reducing overall spring weight and improving vehicle performance without compromising reliability.
3Ease of operation
If the elastic return portion geometry allows easy assembly, then assembly is simplified, but the spring is susceptible to plastic deformation during assembly and maintenance
Solution Approach 1:
The patent introduces a localized reinforcement feature (second portion with increased wall thickness or material strength) at the elastic return portion. This local quality enhancement provides deformation resistance exactly where needed during assembly and maintenance, while maintaining overall geometric simplicity for ease of assembly.
4Adaptability or versatility
If separate shaped and bent sheet metal pieces are assembled for pad-holding spring and pad return spring, then customization is possible, but envelope and weight gain occur
Solution Approach 1:
The patent merges the pad-holding spring and pad return spring into a single integrated component. The spring assembly includes both functions in one piece, eliminating the need for separate components and their associated assembly operations. This reduces envelope and weight while maintaining customization capability through varied geometric configurations.
5Ease of operation
If the elastic return portion bends in the axial direction, then the spring can be assembled, but the bending geometry creates significant axial rigidity and large loads during pad wear
Solution Approach 1:
The patent changes the bending plane of the elastic return portion from axial to radial direction. The elastic return portion now bends perpendicular to the axial direction, which maintains assembly feasibility while dramatically reducing axial rigidity and the resulting loads on the pad during wear.
6Ease of manufacture
If a one-piece shaped and bent sheet metal spring is used for both pad-holding and pad return functions, then production is simplified, but different spring types are needed for each disc brake application
Solution Approach 1:
The patent designs a universal spring assembly that performs both pad-holding and pad return functions in a single component. By optimizing the geometric parameters (radius, wall thickness, material properties) of this multi-functional spring, it can be adapted to various disc brake applications without requiring completely different spring types, thus improving both manufacturing efficiency and application versatility.
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
This solution reduces residual torque, minimizes brake pad wear, and increases the service life of the springs, allowing for versatile application across different caliper geometries with reduced maintenance needs and improved braking efficiency.
Implementation Method 1
a wire spring adapted to be arranged between the C-shaped section and the brake pad and having a longitudinal extension along the axial direction with a first end configured to be operatively connected to the C-shaped section and a second end configured to be operatively connected to the brake pad
Implementation Method 2
with a winding portion extending in a longitudinal spring direction with bends in a bending plane perpendicular to the axial direction
Data Source
AI summary
A pad-holding spring and pad return spring assembly for a brake caliper may have at least one pad-holding spring arranged between at least one guiding ear of a brake pad and a caliper body to bias the brake pad, and a pad return spring. The pad-holding spring has a main extension and at least one C-shaped section. The pad return spring may have an anchoring portion connected to the C-shaped section, a coupling portion to couple the brake pad, and a linking arm connected to the anchoring portion and the coupling portion. The coupling portion is movable with respect to the anchoring portion between a retracted resting position and at least one advanced position, towards the disc, and vice versa. The pad return spring may have at least one winding portion connecting the linking arm to the anchoring portion.