Disc Brake Clip Geometry for Stable Pad Retraction Load
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Solution Overview
Problem
Existing brake clips in disc brake assemblies experience increased retraction load as brake pads wear, leading to undesirable noise and vibration due to vehicle-induced loads, as the retraction load is not effectively managed as the brake pad condition changes from new to worn.
Innovation Solution
A brake clip design featuring a U-shaped section with extension portions and a spring portion, including a transition and application portion, which provides a consistent retraction force by using a plurality of bridging portions and openings to maintain a stable spring force, reducing changes in retraction load as the brake pad wears.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional brake clip with a simple retraction portion is used, then the initial retraction force is sufficient to prevent brake pad contact with the rotor, but the retraction load increases significantly as the brake pad wears, causing noise and vibration
Solution Approach 1:
The brake clip employs a dynamic retraction mechanism where the retraction force is automatically adjusted as the brake pad wears. The extension portion rotates about a pivot point, changing the mechanical advantage ratio between the retraction force application point and the brake pad contact point. This dynamic adjustment ensures that the retraction force remains consistent throughout the brake pad's service life, preventing the noise and vibration that occur with conventional static retraction clips.
Solution Approach 2:
The invention changes the geometric parameters of the brake clip during operation. Specifically, the angle and position of the extension portion relative to the U-shaped section change as the brake pad wears, thereby changing the mechanical advantage ratio. This parameter change allows the system to maintain optimal retraction force despite the varying thickness of the brake pad, resolving the contradiction between initial effectiveness and long-term consistency.
2Reliability
If the retraction force is increased to maintain consistent retraction load, then noise and vibration are reduced, but the brake clip structure becomes more complex
Solution Approach 1:
Rather than adding multiple separate components to maintain consistent retraction force, the invention uses a dynamic single-component design. The extension portion of the brake clip rotates about a pivot point, creating a dynamic mechanical advantage system that automatically adjusts the retraction force. This approach maintains reliability without significantly increasing structural complexity, as it modifies the geometry of an existing component rather than adding new ones.
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 brake clip design effectively reduces changes in retraction load, minimizing noise and vibration by maintaining a consistent spring force, thus enhancing the operational stability and quiet operation of disc brake assemblies over the life of the brake pads.
Implementation Method 1
The spring portion connects the transition portion to the application portion. The spring portion has a plurality of bridging portions interspaced with a plurality of openings
Data Source
AI summary
A disc brake assembly includes a brake clip having a U-shaped section and at least one extension portion. The U-shaped section has a base leg and opposing upper and lower legs extending from the base leg. The at least one extension portion has an application portion, a transition portion with first and second legs, and a bend connecting the first and second legs. The transition portion extends in a first direction from a side of the U-shaped section. The first and second legs extend in a direction other than the first direction. The bend redirects the application portion from a second direction to a third direction. The second direction is angled from the first direction.