Brake Caliper Spring Assembly to Limit Pad Spring Friction
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Solution Overview
Problem
Existing brake caliper spring assemblies face issues with residual torque, vibration, and maintenance due to frictional contact between the pad return spring and pad-holding spring, leading to uneven wear and reduced reliability, especially under high friction material wear conditions.
Innovation Solution
A pad-holding spring and pad return spring assembly where the pad return spring is shaped to minimize contact area with the pad-holding spring, using a wire spring with a winding portion that reduces friction and prevents the spring from becoming stuck or disconnected, ensuring reliable operation and reduced maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the coupling portion of the wire pad return spring is connected to the brake pad without tangential constraint, then the spring can be easily assembled and manufactured, but the coupling portion slides tangentially on the pad plate causing uncoupling or wedging that impairs operation
Solution Approach 1:
The patent applies local quality by creating a specific tangential constraint structure at the coupling portion between the wire pad return spring and brake pad. The constraint is localized to prevent sliding only in the tangential direction while allowing necessary movements, thus maintaining ease of assembly while improving operational reliability.
Solution Approach 2:
The patent introduces an intermediary tangential constraint structure that mediates between the coupling portion of the spring and the brake pad. This intermediary element prevents direct sliding contact that causes uncoupling or wedging, while still allowing the spring to perform its return function reliably.
2Power
If the wire pad return spring is used in high friction material wear conditions, then the spring can handle high performance braking, but the tangential sliding biases the elastic return portion until it contacts the pad-holding spring wall generating friction that adversely affects performance
Solution Approach 1:
The patent applies local quality by providing tangential constraint specifically at the coupling portion where sliding occurs during high wear conditions. This localized constraint prevents the biasing of the elastic return portion and eliminates unwanted friction contact with the pad-holding spring wall, maintaining brake caliper performance under high power braking conditions.
Solution Approach 2:
The patent applies preliminary anti-action by pre-installing the tangential constraint structure before operation. This constraint proactively prevents the sliding and subsequent friction problems that would occur during high friction material wear conditions, ensuring reliable performance from the start.
3Device complexity
If the coupling portion slides tangentially on the pad plate, then assembly is simpler, but the sliding causes the coupling portion to uncouple from the pad or become wedged between the pad and pad-holding spring
Solution Approach 1:
The patent applies local quality by introducing a tangential constraint specifically at the coupling portion without complicating the overall spring structure. The constraint is localized to prevent uncoupling and wedging while maintaining the simplicity of the wire spring design and assembly process.
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 residual torque, minimizes vibration, and increases the service life of the spring assembly by limiting frictional contact and preventing disconnection, resulting in improved braking efficiency and reduced maintenance needs.
Implementation Method 1
pad-holding spring and pad return spring assembly capable of biasing a brake pad in axial, circumferential, and radial directions to reduce vibration and move the pad away from the brake disc
Data Source
AI summary
A pad-holding spring and pad return spring assembly for a brake caliper may have a caliper body adapted to be arranged straddling a brake disc and a one pad-holding spring configured to be arranged between at least one guiding ear of a brake pad housed in the caliper body and the caliper body to bias the brake pad, and a pad return spring configured to bias the brake pad away from a brake disc. The pad-holding spring may have one C-shaped section. The pad return spring may have an anchoring portion operatively connected to the C-shaped section, a coupling portion configured to couple the brake pad, and a linking arm. The coupling portion is elastically movable with respect to the anchoring portion between a retracted resting position and at least one advanced position, towards the disc, and vice versa.