Brake Pad Liner Structure for Gap Control and Pad Return
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Solution Overview
Problem
Conventional brake devices experience reduced braking performance, noise, and drag due to clearance between the pad liner, brake pad, and caliper, leading to incomplete return operation and misalignment of the brake pad.
Innovation Solution
A pad liner design with a first pad clip surrounding a side protrusion of the brake pad, a torque support, and a return spring that includes a second pad clip with a U-shaped return elastic portion, reducing the gap between the reference surface and vertical elastic portion, and providing increased return elastic force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional pad liner structure is used with elastic portions to support the brake pad, then the brake pad can be supported to prevent sagging, but clearance between the pad liner, brake pad, and caliper reduces braking performance and generates noise
Solution Approach 1:
The pad liner is divided into multiple functional segments: a first pad clip for positioning, a vertical elastic portion for support, a torque support for lateral stability, and a return spring for reset. This segmentation allows each component to address specific issues independently, reducing overall clearance while maintaining support functionality.
Solution Approach 2:
The second pad clip is nested within the first pad clip, creating a layered structure that provides both positioning and elastic support functions in a compact arrangement. This nesting reduces the overall footprint while maintaining the necessary clearance reduction effects.
2Stability of the object's composition
If elastic portions are added to the pad liner to prevent brake pad vibration, then return operation is improved, but device complexity increases
Solution Approach 1:
The return spring integrates multiple functions: it provides elastic support for return operation, acts as a positioning element, and works in conjunction with the pad clips to maintain brake pad alignment. This merging reduces the need for separate components while achieving stable return operation.
Solution Approach 2:
The first pad clip serves multiple purposes: it positions the brake pad laterally, provides a mounting point for the return spring, and works with the torque support to prevent rotation. This multi-functionality reduces overall device complexity while maintaining stability.
3Productivity
If the gap between reference surface and vertical elastic portion is reduced to minimize clearance, then braking performance improves, but manufacturing precision requirements increase
Solution Approach 1:
The design changes the structural parameters of the pad liner, specifically the geometry of the first pad clip and vertical elastic portion, to inherently minimize clearance. By optimizing these parameters during design, the need for tight manufacturing tolerances is reduced while still achieving minimal gap for improved braking performance.
Solution Approach 2:
The vertical elastic portion acts as an intermediary element that accommodates manufacturing variations while maintaining consistent contact between the pad liner and brake pad. This elastic mediation allows for parameter optimization without requiring extremely tight manufacturing precision.
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 pad liner minimizes vertical gap, maintains constant lateral gap, and enhances brake pad alignment, reducing noise and improving braking performance by providing greater return force than the pad sliding force.
Implementation Method 1
a vertical elastic portion located on an opposite side of the reference surface and pressurizing the side protrusion in a direction of the reference surface
Implementation Method 2
a return spring that includes a second pad clip with a U-shaped return elastic portion
Implementation Method 3
a torque support located under the first pad clip and located between a side surface of the brake pad and the caliper body, wherein the torque support supports a braking torque
Data Source
AI summary
A pad liner includes a first pad clip that surrounds and is coupled to a side protrusion protruding in a lateral direction from a brake pad, and a torque support located under the first pad clip and between a side surface of the brake pad and the caliper body. The torque support supports a braking torque. The first pad clip includes a reference surface located on one of a top surface and a bottom surface of the side protrusion, a vertical elastic portion located on an opposite side from the reference surface that pressurizes the side protrusion in a direction of the reference surface, and a clip side portion that connects the reference surface and the vertical elastic portion and surrounds a side surface of the side protrusion. The pad liner minimizes a vertical gap and movement of the brake pad.