Brake Pad Spring Assembly for Axial Pad Retraction
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Solution Overview
Problem
Existing brake caliper systems experience residual braking torque and uneven wear due to misalignment of brake pads with the disc, leading to increased maintenance and noise, as well as reduced cooling capacity and potential damage to dust boots from traditional spring solutions.
Innovation Solution
A pad-and-spring assembly that applies an elastic biasing action in the axial direction to move the brake pad away from the disc when braking ceases, using a design that avoids direct coupling with the piston to minimize misalignment and maintain heat exchange efficiency, featuring a supporting plate with a free surface and through openings for the elastic device to apply a direct axial bias without interfering with the piston footprint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional spring solutions are used to apply elastic biasing action on brake pads, then residual braking torque is reduced, but misalignment of brake pads with the disc occurs leading to uneven wear and increased noise
Solution Approach 1:
The patent introduces an intermediary elastic element (spring) that is strategically positioned and configured to apply biasing force to the brake pad without directly interfering with the alignment mechanism. The spring acts as a mediator between the caliper body and the brake pad, providing the necessary elastic biasing action while the caliper body's geometric features (such as guide surfaces and positioning elements) ensure proper alignment is maintained despite the spring's presence.
2Reliability
If springs are coupled to the piston to apply elastic biasing action, then residual braking torque is reduced, but cooling capacity is reduced and dust boot damage occurs
Solution Approach 1:
The patent extracts the elastic biasing function from the piston assembly and relocates it to a separate spring mechanism mounted on the caliper body. This separation removes the spring from the piston's thermal pathway, allowing the piston to maintain full contact with the brake pad for effective heat transfer. The spring is positioned in a location that does not obstruct the piston's thermal management function or compromise the dust boot's protective role.
3Manufacturing precision
If elastic devices are positioned to apply direct axial bias without interfering with piston footprint, then misalignment is minimized, but device complexity increases
Solution Approach 1:
The patent designs the caliper body to serve multiple functions: it provides structural support, guides brake pad movement, positions the elastic biasing element, and maintains alignment throughout operation. The caliper body integrates guide surfaces, positioning features, and mounting structures for the spring into a single component, reducing the need for additional separate alignment mechanisms and thereby limiting the increase in overall device complexity.
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 effectively reduces residual braking torque, promotes even wear of the friction material, and maintains the cooling capacity of the brake system while minimizing the risk of misalignment and damage to the dust boot.
Implementation Method 1
said at least one elastic device 5 being adapted to apply an elastic biasing action directed in axial direction (X-X) to said brake pad 2 to move it away from the brake disc when the braking action ceases
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
A pad-and-spring assembly (1) for a brake caliper (10) for a disc brake comprising: at least one brake pad (2) comprising friction material (3) and a supporting plate (4) which supports said friction material (3); at least one elastic device (5), adapted to apply an elastic biasing action directed in axial direction to said brake pad (2) to move it away from the brake disc when the braking action ceases; wherein said supporting plate (4) comprises a surface facing the disc (6), intimately associated with said friction material (3), and a plate back (7), axially opposite to said disc facing surface (6) and adapted to face thrust means (8) of the brake caliper (10) which can be associated with said assembly (1); said friction material (3) comprises a radially inner edge, adapted to face the rotation axis of the brake disc, and a radially outer edge (13), radially opposite to said radially inner edge; said radially outer edge (13) of the friction material (3) defines the outer radial dimension level of the friction material (3) with its tangential extension on said surface facing the disc (6) of the supporting plate (4); said disc facing surface (6) of the supporting plate (4) comprises at least one free surface (9), which is free from the contact with the friction material (3) and adapted to face a braking surface of the brake disc which can be associated with said assembly (1), wherein said free portion (9) is located radially inside with respect to said at least one tangential extension of the radially outer edge (13) of the friction material (3); said free surface (9) of the disc facing surface (6) of the supporting plate (4) of brake pad (2) comprises at least one through opening edge (16) which at least partially delimits a through opening (17) in axial direction through said supporting plate (4) of brake pad (2); wherein said at least one elastic device (5) has a body comprising: at least one connecting portion (21, 21'), adapted to connect to the body of the brake caliper (10) which can be associated with said assembly (1); at least one supporting portion (22), which rests against said through opening edge (16) of the free surface (9) of the supporting plate (4), axially crossing said through opening (17) of the supporting plate (4) to apply an elastic biasing action directly in axial direction to said through opening edge (16) of said through opening (17).