Disc Brake Pad Clip Assembly for Common Clips and Return Springs
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Solution Overview
Problem
The existing design of floating type disc brakes requires separate pad clips on the axially inner and outer sides, which complicates the manufacturing process and increases costs due to the need for different thickness dimensions, and also challenges the integration of return springs without impairing their function.
Innovation Solution
The design incorporates separate pad clips on the axially inner and outer sides with a spring holding portion to securely attach return springs, allowing for commonality in manufacturing and maintaining the functionality of the pad clips, including a U-shaped clamping portion, radial pressing, circumferential pressing, and spring holding features to manage the return springs effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate pad clips are designed for axially inner and outer sides with different thickness dimensions, then the pad clip can fit different rotor thicknesses, but the manufacturing process becomes complicated and costs increase
Solution Approach 1:
The pad clip is designed with a universal structure that can accommodate different rotor thicknesses. The clip includes a body portion with a through hole and elastic pressing portions that can adapt to various thickness dimensions without requiring different clip designs, thus maintaining manufacturing simplicity while achieving versatility.
Solution Approach 2:
The pad clip utilizes elastic deformation of its pressing portions to adapt to different rotor thicknesses. The elastic pressing portions can deflect inward or outward dynamically, allowing the same clip design to fit multiple rotor thickness specifications without compromising the manufacturing process.
2Reliability
If separate pad clips are designed for axially inner and outer sides, then each pad clip can be optimized for its specific position, but the number of parts increases and assembly becomes more complex
Solution Approach 1:
A single pad clip design serves both axially inner and outer side functions. The universal clip structure maintains position-specific optimization capabilities while reducing the total number of different part types, thereby simplifying inventory management and assembly procedures.
3Ease of manufacture
If return springs are integrated into the pad clip structure, then the assembly process is simplified, but the pad clip structure becomes more complex
Solution Approach 1:
The return spring is nested within the through hole of the pad clip body portion. This nesting arrangement allows the return spring to be securely held by the pad clip structure without adding external complexity, achieving easy assembly while maintaining a compact integrated design.
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 configuration reduces manufacturing costs by allowing common pad clip designs for different rotor thicknesses and ensures the return springs are securely held without interfering with the pad clip's function, enhancing the assembly process and operational efficiency of the floating type disc brake.
Implementation Method 1
a clamping portion (30) that has a substantially U-shaped cross section and is configured to elastically clamp a projection portion (25) provided on the circumferentially inner side surface of the pad guide portion (11c) from both radial sides
Implementation Method 2
a radial pressing portion (32) that is disposed at inward than the clamping portion (30) in the radial direction and is configured to press outward in the radial direction an ear portion (12a) provided on the circumferentially outer side portion of the pad (4a)
Implementation Method 3
a circumferential pressing portion (33) that extends outward in the radial direction from a radially outer side portion of the clamping portion (30), an intermediate portion (33b) of which is folded back inward in a circumferential direction of the rotor (8) and is folded back inward in the radial direction, and a tip end portion (33c) of which is configured to press the pad (4a) inward in the circumferential direction
Implementation Method 4
return springs (24a to 24d) that respectively are held on the pad clips (23a to 23d) and are configured to press the pads (4a, 5a) away from the rotor (8) in an axial direction of the rotor (8)
Data Source
AI summary
A pad clip for a disc brake includes: a radial pressing portion which is disposed at inward than a clamping portion in a radial direction and presses outward in the radial direction an ear portion; a circumferential pressing portion which extends outward in the radial direction from a radially outer side portion of the clamping portion, an intermediate portion thereof being folded back inward in radial and circumferential directions of the rotor, and a tip end portion thereof pressing the pad inward in the circumferential direction; and a spring holding portion which protrudes outward in the circumferential direction from the radially outer side portion of the clamping portion than a base portion of the circumferential pressing portion, and holds a return spring which is made of wire material and presses the pad away from the rotor in an axial direction of the rotor.