Disc Brake Pad Spring Assembly With Multi-Directional Pad Bias
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Solution Overview
Problem
Existing disc brake systems suffer from residual braking torque and noise due to pad contact with the brake disc during release, leading to increased maintenance and fuel consumption, and known spring solutions are either inefficient in reducing noise or complicate assembly and manufacturing with strict tolerances.
Innovation Solution
A spring device with a prevalent longitudinal development, featuring coupling and thrust portions with cradles and ramp surfaces that apply axial, tangential, and radial bias to brake pads, reducing radial dimension and enabling efficient noise reduction while simplifying assembly and manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If springs are used to apply axial thrust action on pads to separate them from brake disc, then residual braking torque and noise are reduced, but device complexity increases
Solution Approach 1:
The spring device is divided into multiple independent thrust portions (first thrust portion and second thrust portion) that can be separately positioned and adjusted. Each thrust portion can be independently configured to apply force at different locations on the brake pad, allowing complex separation movements to be achieved through simpler, modular components rather than a single complex spring mechanism.
Solution Approach 2:
The spring device applies thrust forces in multiple directions simultaneously - axial direction (away from disc), radial direction (inner radial direction), and tangential direction (opposite to rotation). This multi-dimensional force application enables the brake pad to be separated from the disc while controlled against the rest surface, achieving noise reduction through three-dimensional positioning rather than simple axial movement.
2Object-affected harmful factors
If springs apply thrust action in circumferential direction to settle pad against rest, then noise from pad acceleration is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The spring device automatically positions the brake pad against the rest surface through its inherent elastic thrust action in tangential direction. The spring's preloaded configuration ensures that during normal operation and release phases, the pad is self-biased against the rest without requiring precision-adjusted mechanical stops or complex positioning mechanisms. The system uses the spring's own elastic properties to maintain proper pad positioning.
Solution Approach 2:
The spring device configuration can be adjusted by modifying parameters such as spring preload, thrust portion positions, and mounting locations. These parameter changes allow the tangential thrust force to be optimized for different operating conditions, enabling the system to accommodate variations in manufacturing tolerances while maintaining effective noise reduction performance.
3Ease of operation
If multiple thrust portions are provided to apply multi-directional bias, then pad separation and noise reduction are improved, but device complexity increases
Solution Approach 1:
Each thrust portion of the spring device is designed to perform multiple functions simultaneously. The same thrust portion that applies axial force for pad separation also contributes to radial positioning and tangential biasing against the rest. This multi-functionality allows the system to achieve complex three-dimensional pad control without proportionally increasing the number of separate components, as each component serves multiple purposes in the overall pad positioning strategy.
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 noise and residual braking torque, maintains compact dimensions, and simplifies assembly, providing a quiet and efficient braking action while minimizing maintenance needs.
Implementation Method 1
a spring device (10) for a disc brake (3)... comprising a spring body (11) having prevalent longitudinal development... adapted to bias at least one brake pad (8, 9)... in axial direction away from the disc (4), in inner radial direction (RI), and in tangential direction (T-T)
Data Source
AI summary
A spring device for a disc brake, a pad and spring assembly for a disc brake, a brake caliper, and a disc brake is described. The spring device may have a spring body having prevalently longitudinal development, with at least one coupling portion, to couple in a snapping manner the spring device to a portion of an associable brake caliper in a removable manner. The spring pad assembly may have at least one brake pad having at least one ramp surface, inclined with respect to the radial direction and to the tangential direction, which forms an abutment reference for the at least one thrust surface of the spring device. The at least one ramp surface of the support plate puts in traction the spring device.